Communication cables incorporating twisted pair components

ABSTRACT

Communication cables incorporating a plurality of twisted pair components formed around a central member are described. A central member may extend lengthwise along a longitudinal length of a cable, and the central member may include a channel extending lengthwise that defines a longitudinal cavity through the central member. A plurality of twisted pair components may be formed around the central member, and each component may include a plurality of twisted pairs of individually insulated electrical conductors and at least one shield layer. The shield layer may include electrically conductive material, and the shield layer may be formed around at least one of the plurality of twisted pairs. Additionally, the shield layer may be in direct contact with the central member. Further, a jacket may be formed around the central member and the plurality of twisted pair components.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to pending U.S. patent application Ser. No.15/098,626, filed Apr. 14, 2016 and entitled “Communication CablesIncorporating Twisted Pair Separators with Cooling Channels”; and U.S.patent application Ser. No. 15/098,635, filed Apr. 14, 2016 and entitled“Communication Cables Incorporating Twisted Pair Separators.” Thecontents of each of these applications is incorporated herein byreference in its entirety.

TECHNICAL FIELD

Embodiments of the disclosure relate generally to communication cablesand, more particularly, to cables incorporating a plurality ofunjacketed twisted pair components formed around a central member ofother components that assists in cooling the cable.

BACKGROUND

A wide variety of different types of communication cables incorporatetwisted pair conductors. In a wide variety of applications, when atwisted pair cable is installed and utilized, relatively higher amountsof heat may be generated in certain portions of the cable. For example,with a cable installed in a data center, portions of the cable situatedin relatively close proximity to electronic equipment and/or equipmentcabinets (e.g., portions of the cable near terminating ends) may becomehotter than other portions of the cable. Additionally, electronicequipment connected to or near the termination ends of the cable maygenerate heat. The heat may negatively impact both the electricalperformance of the cable and the performance of electronic equipmentassociated with the cable. Further, when a plurality of twisted paircables are used in relatively close proximity to one another, relativelyhigher amounts of heat may be generated, thereby exacerbating electricalperformance issues. Accordingly, there is an opportunity for improvedcables that provide for heat transfer that assists in cooling the cableand/or any associated electronic equipment.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanyingfigures. In the figures, the left-most digit(s) of a reference numberidentifies the figure in which the reference number first appears. Theuse of the same reference numbers in different figures indicates similaror identical items; however, various embodiments may utilize elementsand/or components other than those illustrated in the figures.Additionally, the drawings are provided to illustrate exampleembodiments described herein and are not intended to limit the scope ofthe disclosure.

FIGS. 1-3 are cross-sectional views of example cables that include aplurality of twisted pair components formed around a central coolingmember, according to illustrative embodiments of the disclosure.

FIGS. 4A-4D are cross-sectional views of example twisted pair componentsthat may be incorporated into cables, according to illustrativeembodiments of the disclosure.

FIGS. 5A-5I are perspective views of example central members that may beincorporated into cables in accordance with various illustrativeembodiments of the disclosure.

FIGS. 6A-6H are cross-sectional views of example central members thatmay be incorporated into cables in accordance with various illustrativeembodiments of the disclosure.

FIGS. 7A-7G are top level views of various configurations ofelectrically conductive material that may be incorporated into shieldelements as desired in various embodiments of the disclosure.

DETAILED DESCRIPTION

Various embodiments of the present disclosure are directed to cablesthat include a plurality of twisted pair components formed or positionedaround a cooling tube or central member. A cable jacket may be formedaround the plurality of twisted pair components and the central member;however, in certain embodiments, the plurality of twisted paircomponents may be unjacketed. In other words, a plurality of unjacketedtwisted pair cores, such as the cores incorporated into Ethernet or datacables (e.g., Category 5, Category 5e, Category 6, Category 6A, Category8, etc.) may be formed around a central member that assists in coolingthe cores. When installed in a suitable environment, heat generated byand/or in the various twisted pair cores or components may bedissipated, transferred, and/or otherwise mitigated by the centralmember. For example, when installed in a data center, heat may betransferred or mitigating, thereby improving the electrical performanceof the cable. As another example, when the cable is utilized to transferpower such as in power over Ethernet applications, the heat transfercooling effect may facilitate improved cable performance (e.g., a higherpower rating, etc.).

Each of the plurality of twisted pair components or cores may include aplurality of twisted pairs of individually insulated conductors and atleast one shield layer. Additionally, each shield layer may be formedaround one or more of the twisted pairs included in a twisted paircomponent. For example, each twisted pair may be individually shieldedand/or an overall shield may be formed around the plurality of twistedpairs in component. Due to the unjacketed nature of the twisted paircomponents, one or more of the shield layers incorporated into a twistedpair component may contact or be positioned immediately adjacent to thecentral member. In operation, the shield layers may function as heatsinks that draw heat away from the twisted pair conductors, and the heatmay be more readily transferred to the central member.

The central member may be formed with a wide variety of suitablecross-sectional shapes and/or dimensions. According to an aspect of thedisclosure, the central member may include at least one longitudinallyextending channel that defines a lengthwise cavity through the centralmember. In various embodiments, fluid may be positioned within thechannel, such as air, other gas(es), one or more coolant(s), or othersuitable fluids. The at least one longitudinally extending channel (alsoreferred to as the longitudinal channel) may assist in convective heattransfer along a longitudinal length of the cable. As portions of thecable and/or the various twisted pair components heat up, the fluidwithin the longitudinal channel may transfer heat from the relativelywarmer or hotter portions along the longitudinal length of the cable. Incertain embodiments, the convective heat transfer may occur basedprimarily on temperature fluctuations within the cable and/or thelongitudinal channel. In other embodiments, heat sinks may beincorporated into the longitudinal channel and/or other components ofthe central member in order to improve the convective heat transfer. Inyet other embodiments, one or more fans and/or circulation systems maybe connected to the cable to improve heat transfer. The convective heattransfer may facilitate or assist in normalization of the temperaturealong the longitudinal length of the cable. As a result, in certainembodiments, the electrical performance of the cable and/or electronicequipment associated with the cable may be improved.

In certain embodiments, the central member may additionally include oneor more second channels that extend from a longitudinal channel throughthe central member, for example, to an outer surface of the centralmember. These second channels may further facilitate convective heattransfer via the central member. As discussed in greater detail below,any number, configurations, and/or arrangements of second channels maybe utilized. As desired in various embodiments, a central member mayadditionally provide electromagnetic shielding for one or more of thetwisted pair components. A wide variety of different types of materialsmay be utilized to provide shielding, such as electrically conductivematerial, semi-conductive material, and/or dielectric shieldingmaterial. Additionally, shielding material may be incorporated into thecentral member at a wide variety of locations, for example, on one ormore surfaces and/or embedded within the central member. In certainembodiments, the central member may even be formed from a material thatprovides shielding. In other embodiments, either continuous shieldingmaterial or a plurality of discontinuous patches of shielding materialmay be formed on one or more surfaces of the central member, such as anexternal surface of the central member, on a surface of a cavity definedby the longitudinal channel, and/or within one or more second channels.A wide variety of suitable configurations and/or patterns ofelectrically conductive material may be formed as desired in variousembodiments.

Embodiments of the disclosure now will be described more fullyhereinafter with reference to the accompanying drawings, in whichcertain embodiments of the disclosure are shown. This invention may,however, be embodied in many different forms and should not be construedas limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the invention to thoseskilled in the art. Like numbers refer to like elements throughout.

Example Cable Constructions

With reference to FIG. 1, a cross-section of an example cable 100 thatmay be utilized in various embodiments is illustrated. The cable 100 isillustrated as a twisted pair communications cable; however, other typesof cables may be utilized, such as composite or hybrid cables thatinclude a combination of twisted pairs and other transmission media(e.g., optical fibers, etc.). Indeed, suitable cables may include anynumber of transmission media including but not limited to one or moretwisted pairs, optical fibers, coaxial cables, and/or power conductors.Additionally, embodiments of the disclosure may be utilized inassociation with horizontal cables, vertical cables, flexible cables,equipment cords, plenum cables, riser cables, or any other appropriatecables.

As shown in FIG. 1, the cable 100 may include a plurality of twistedpair components 105A-F arranged or positioned around a central member110. The central member 110 may facilitate convective heat transferwithin the cable, thereby assisting in cooling and/or normalizing thetemperature of the twisted pair components. An outer jacket 115 may thenbe formed around the twisted pair components 105A-F and the centralmember 110. The cable 100 of FIG. 1 includes six twisted pair components105A-F formed around the central member 110. In this six around onedesign, the central member 110 may have a size (e.g., diameter,cross-sectional area, etc.) that is approximately equal to that of eachof the twisted pair components 105A-F. In other embodiments, otherarrangements and/or dimensions may be utilized for the central member110 and twisted pair components 105A-F. Additionally, components otherthan twisted pair components may be arranged or positioned around thecentral member 110. Each of the components illustrated in FIG. 1 isdescribed in greater detail below.

Any number of twisted pair components, such as the illustrated sixtwisted pair components 105A-F may be incorporated into the cable 100.Additionally, in certain embodiments, the twisted pair components 105A-Fmay be formed or positioned around the central member 110 at any givencross-sectional point along a longitudinal length of the cable. Forexample, the twisted pair components 105A-F may be stranded or helicallytwisted about the central member 110 with a wide variety of suitablepitches or twist lays. For example, in certain embodiments, the twistedpair components 105A-F may be stranded around the central member 110with a twist lay between approximately 150 mm and approximately 1800 mm.

Although the cable 100 of FIG. 1 illustrates a single layer or ring oftwisted pair components 105A-F formed around the central member 100, inother embodiments, a plurality of layers or rings of twisted paircomponents may be incorporated into the cable 100. Additionally oralternatively, in certain embodiments, components other than twistedpair components may be incorporated into a cable. For example, opticalfiber cable components, coaxial cable components, power cablecomponents, spacers, and/or a wide variety of other suitable componentsmay be incorporated into one or more layers that are stranded around thecentral member 110.

In certain embodiments, each of the twisted pair components 105A-F mayinclude components similar to a conventional twisted pair cable, such asa conventional four pair cable; however, the twisted pair components105A-F may be formed without outer jackets. Accordingly, each of thetwisted pair components may be similar to a core of a conventionaltwisted pair cable. An example twisted pair component, twisted pairsubunit, or twisted pair core (generally referred to as twisted paircomponent 105 or core 105) may include a plurality of twisted pairs120A-D and at least one shield layer 125. In certain embodiments, anoverall shield layer 125 may be formed around the plurality of twistedpairs 120A-D. In other embodiments, individual shield layers may berespectively formed around each of the twisted pairs 120A-D and/orshield layers may be formed around one or more groups of twisted pairs120A-D. Indeed, a wide variety of suitable shielding arrangements and/orcombinations of shielding arrangements may be utilized. Additionally,given the unjacketed nature of the twisted pair component 105, (at leastfor a twisted pair component incorporated into an inner ring formedaround the central member 110) one or more shield layers incorporatedinto the twisted pair component 105 may contact the central member 110.

Although the twisted pair component 105 is illustrated as having fourtwisted pairs 105A. 105B, 105C, 105D, any other suitable number of pairsmay be utilized. As desired, the twisted pairs 105A-D may be twisted orbundled together and/or suitable bindings may be wrapped around thetwisted pairs 105A-D. In other embodiments, multiple grouping of twistedpairs may be incorporated into a twisted pair component 105. As desired,each grouping may be twisted, bundled, and/or bound together. Further,in certain embodiments, the multiple groupings may be twisted, bundled,or bound together.

Each twisted pair (referred to generally as twisted pair 120 orcollectively as twisted pairs 120) may include two electricalconductors, each covered with suitable insulation. Each twisted pair 120can carry data or some other form of information, for example in a rangeof about one to ten Giga bits per second (“Gbps”) or another appropriatefrequency, whether faster or slower. As desired, each of the twistedpairs may have the same twist lay length or alternatively, at least twoof the twisted pairs may include a different twist lay length. Forexample, each twisted pair may have a different twist rate. Thedifferent twist lay lengths may function to reduce crosstalk between thetwisted pairs. A wide variety of suitable twist lay lengthconfigurations may be utilized. Additionally, in certain embodiments,each of the twisted pairs 120A-D may be twisted in the same direction(e.g., clockwise, counter clockwise). In other embodiments, at least twoof the twisted pairs 120A-D may be twisted in opposite directions.Further, as desired in various embodiments, one or more of the twistedpairs 120A-D may be twisted in the same direction as an overall bunchlay of the combined twisted pairs. In other embodiments, at least one ofthe twisted pairs 120A-D may have a pair twist direction that isopposite that of the overall bunch lay.

The electrical conductors of a twisted pair 120 may be formed from anysuitable electrically conductive material, such as copper, aluminum,silver, annealed copper, gold, a conductive alloy, etc. Additionally,the electrical conductors may have any suitable diameter, gauge, and/orother dimensions. Further, each of the electrical conductors may beformed as either a solid conductor or as a conductor that includes aplurality of conductive strands that are twisted together.

The twisted pair insulation may include any suitable dielectricmaterials and/or combination of materials, such as one or more polymericmaterials, one or more polyolefins (e.g., polyethylene, polypropylene,etc.), one or more fluoropolymers (e.g., fluorinated ethylene propylene(“FEP”), melt processable fluoropolymers, MFA, PFA, ethylenetetrafluoroethylene (“ETFE”), ethylene chlorotrifluoroethylene(“ECTFE”), etc.), one or more polyesters, polyvinyl chloride (“PVC”),one or more flame retardant olefins (e.g., flame retardant polyethylene(“FRPE”), flame retardant polypropylene (“FRPP”), a low smoke zerohalogen (“LSZH”) material, etc.), polyurethane, neoprene,cholorosulphonated polyethylene, flame retardant PVC, low temperatureoil resistant PVC, flame retardant polyurethane, flexible PVC, or acombination of any of the above materials. Additionally, in certainembodiments, the insulation of each of the electrical conductorsutilized in the twisted pairs 120A-D may be formed from similarmaterials. In other embodiments, at least two of the twisted pairs mayutilize different insulation materials. For example, a first twistedpair may utilize an FEP insulation while a second twisted pair utilizesa non-FEP polymeric insulation. In yet other embodiments, the twoconductors that make up a twisted pair may utilize different insulationmaterials.

In certain embodiments, the insulation may be formed from multiplelayers of one or a plurality of suitable materials. In otherembodiments, the insulation may be formed from one or more layers offoamed material. As desired, different foaming levels may be utilizedfor different twisted pairs in accordance with twist lay length toresult in insulated twisted pairs having an equivalent or approximatelyequivalent overall diameter. In certain embodiments, the differentfoaming levels may also assist in balancing propagation delays betweenthe twisted pairs. As desired, the insulation may additionally includeother materials, such as a flame retardant materials, smoke suppressantmaterials, etc.

With continued reference to the twisted pair component 105, one or moreshield layers may be formed around the twisted pairs 120A-D. Forexample, as shown in FIG. 1, an overall shield 125 may be formed aroundthe collective plurality or group of twisted pairs 120A-D. As anotherexample, as illustrated in FIG. 2, individual shields may be providedfor each of the twisted pairs. In other embodiments, shield layers maybe provided for any desired groupings of twisted pairs. In yet otherembodiments, twisted pairs may be formed with a component that functionsas both a dielectric separator positioned between the conductors of thetwisted pair and as a shield element. As desired in various embodiments,multiple shield layers and/or types of shield layers may be provided,for example, individual shields and an overall shield. One or moreshield layers may incorporate electrically conductive material,semi-conductive material, or dielectric shielding material in order toprovide electrical shielding for one or more cable components.

Various embodiments of the shield layer 125 (or shield 125) illustratedin FIG. 1 are generally described herein; however, it will beappreciated that other shield layers may have similar constructions. Incertain embodiments, a shield 125 may be formed from a single segment orportion that extends along a longitudinal length of the twisted paircomponent 105. In other embodiments, a shield 125 may be formed from aplurality of discrete segments or portions positioned adjacent to oneanother along a longitudinal length of the twisted pair component 105.In the event that discrete segments or portions are utilized, in certainembodiments, gaps or spaces may exist between adjacent segments orportions. In other embodiments, certain segments may overlap oneanother. For example, an overlap may be formed between segmentspositioned adjacent to one another along a longitudinal length of thecable.

As desired, a wide variety of suitable techniques and/or processes maybe utilized to form a shield 125 (or a shield segment). In certainembodiments, a shield 125 may be a relatively continuous shield thatincludes shielding material that extends substantially along alongitudinal length of the shield element. For example, a relativelycontinuous metallic material, semi-conductive material, dielectricshielding material, a braided shielding material, or a foil shield maybe utilized. In other embodiments, a shield 125 may be formed as adiscontinuous shield having a plurality of isolated patches of shieldingmaterial. For example, a base material or dielectric material may beextruded, poltruded, or otherwise formed. Electrically conductivematerial or other shielding material may then be applied to (e.g.,formed on, adhered to, etc.), injected into, embedded in, or otherwisecombined with the base material. In certain embodiments, the base layermay have a substantially uniform composition and/or may be made of awide range of materials. Further, the base layer may be foamed, may be acomposite, and/or may include one or more strength members, fibers,threads, or yarns. As desired, flame retardant material, smokesuppressants, and/or other desired substances may be blended orincorporated into the base layer. Examples of suitable shieldingarrangements that may be utilized in conjunction with the shield 125and/or other shield elements are described in greater detail below.

In certain embodiments, the shield 125 (or individual shield segments)may be formed as a tape that includes both a dielectric layer andshielding material (e.g., copper, aluminum, silver, an alloy, etc.)formed on one or both sides of the dielectric layer. Examples ofsuitable materials that may be used to form a dielectric layer include,but are not limited to, various plastics, one or more polymericmaterials, one or more polyolefins (e.g., polyethylene, polypropylene,etc.), one or more fluoropolymers (e.g., fluorinated ethylene propylene(“FEP”), polyester, polytetrafluoroethylene, polyimide, or some otherpolymer, combination of polymers, or dielectric material(s) that doesnot ordinarily conduct electricity. Shielding material may then bedeposited on, adhered to, or otherwise formed on the dielectric layer.Additionally, in certain embodiments, shielding material may besandwiched between two dielectric layers. In other embodiments, two ormore layers of shielding material may be combined with any number ofsuitable dielectric layers to form the shield 125. Indeed, any number ofsuitable layers of material may be utilized to form a tape which may beused as the shield 125.

According to an aspect of the disclosure, the twisted pair component 105may be an unjacketed component. In other words, no outer jacket layer isformed around the twisted pairs 120A-D and the one or more shieldlayers. In certain embodiments, at least one shield layer may contactthe central member 110. For example, if an outer shield layer 125 isformed around the plurality of twisted pairs 120A-D, the outer shieldlayer 125 may be positioned adjacent to and/or may contact the centralmember 110. As another example, if individual shield layers arerespectively formed around each of the twisted pairs 120A-D, one or moreof the individual shield layers may be positioned adjacent to and/orcontact the central member 110 at any given cross-sectional point alongthe longitudinal length of the cable 100. Additionally, in certainembodiments, a suitable binder may be helically wrapped around theplurality of twisted pairs 120A-D in order to hold the components of thetwisted pair component 105 together. For example, if the twisted pairs120A-D are individually shielded, a binder may be utilized. A binder maybe formed from a wide variety of suitable materials, such as polymericmaterials, water absorbent materials, flame retardant materials, etc.

Given the unjacketed nature of the twisted pair component 105, incertain embodiments, a shield 125 may be designed to be relativelyrugged. In other words, the shield 125 may be less susceptible totearing or other damage than conventional shield layers incorporatedinto jacketed communication cables. A wide variety of suitable designelements may be utilized in order to enhance the ruggedness of theshield 125. In certain embodiments, one or more relatively ruggedmaterials may be utilized to form one or more components of the shield125. For example, a polymeric material may be utilized as a dielectriclayer in a shield 125 in order to attain a desired tensile strength. Inother embodiments, a thickness of one or more components of the shield125, such as a dielectric layer, may be selected in order to obtain adesired tensile strength. In certain example embodiments, a shield 125may be constructed such that it has a load at yield of at leastapproximately 60N.

As a result of being unjacketed, the twisted pair component 105 may beformed with a smaller diameter than conventional twisted pair cables.Conventional twisted pair cable jackets have a thickness betweenapproximately 15 mils (381 μm) and approximately 23 mils (584 μm). Evenif one or more shield layers are thickened in order to improve theirtensile strength relative to conventional shield layers, an overalldiameter of the twisted pair component 105 may be reduced relative toconventional cables. Additionally, when a plurality of twisted paircomponents 105A-F are stranded around a central member 110, an overalldiameter of the cable 100 may be reduced. In certain embodiments, thetwisted pair component 105 may have an outer diameter that is less thanor equal to approximately 7.5 mm.

In certain embodiments, a suitable separator 130 or filler may beincorporated into the twisted pair component 105. The separator 110 orfiller may be configured to orient and or position one or more of thetwisted pairs 120A-D. The orientation of the twisted pairs 120A-Drelative to one another may provide beneficial signal performance. Asdesired in various embodiments, the separator 130 may be formed inaccordance with a wide variety of suitable dimensions, shapes, ordesigns. The separator 130 illustrated in FIG. 1 has an approximatelycross-shaped cross-section. As other examples, a rod-shaped or circularseparator, a flat separator, an X-shaped or cross-shaped separator, aT-shaped separator, a Y-shaped separator, a J-shaped separator, anL-shaped separator, a diamond-shaped separator, a separator having anynumber of spokes extending from a central point, a separator havingwalls or channels with varying thicknesses, a separator having T-shapedmembers extending from a central point or center member, a separatorincluding any number of suitable fins, and/or a wide variety of othershapes may be utilized.

Any number of suitable materials and/or combinations of materials may beutilized to form the separator 130. For example, any of the materialsdiscussed herein as being suitable for forming either the shield layer125 or the central member 110 may also be suitable for forming theseparator 130. Additionally, a wide variety of suitable methods ortechniques may be utilized to form the separator 130. In certainembodiments, material may be extruded through one or more dies and/orvia any number of other suitable extrusion techniques in order to obtaina desired cross-sectional shape. In other embodiments, material may becast or molded into a desired shape to form the separator 130. In yetother embodiments, a tape may be formed into a desired shape utilizing awide variety of folding and/or shaping techniques. For example, arelatively flat tape may be formed into an X-shape or cross-shape as aresult of being passed through one or more dies. Additionally, many ofthe formation techniques and/or example constructions described belowfor the central member 110 may be equally applicable to the separator130.

As desired in various embodiments, the separator 130 may be formed to berelatively continuous along a longitudinal length of the cable 100and/or the twisted pair component 105. In other embodiments, theseparator 130 may be formed from a plurality of severed or discretecomponents that are arranged end-to-end along a longitudinal length.Additionally, in certain embodiments, the separator 130 may include anynumber of longitudinal channels, secondary channels, and/or heat sinksthat provide a cooling function for the twisted pairs 120A-Dincorporated into the twisted pair component 105. As desired, theseparator 130 may also include shielding material, such as shieldingmaterial formed on one or more surfaces of the separator 130, shieldingmaterial embedded in a separator body, and/or shielding material (e.g.,semi-conductive material, dielectric shielding material, etc.) utilizedto form the separator 130 or one or more components of the separator130. Many of these features are discussed in greater detail below withreference to the central member 110, and the discussion may be equallyapplicable to the separator 130. Additionally, various constructionsand/or aspects of twisted pair separators are described in U.S. patentapplication Ser. No. 15/098,626, filed Apr. 14, 2016 and entitled“Communication Cables Incorporating Twisted Pair Separators with CoolingChannels”; and U.S. patent application Ser. No. 15/098,635, filed Apr.14, 2016 and entitled “Communication Cables Incorporating Twisted PairSeparators.” Both of these applications have been incorporated byreference herein in their entirety, and it will be understood that anyof the described separators may be incorporated into the twisted paircomponent 105.

With continued reference to FIG. 1, the central member 110 may bepositioned between the plurality of twisted pair components 105A-F. Thecentral member 110 may include one or more longitudinally extendingchannels or longitudinal channels that facilitate convective heattransfer within the cable 100. In this regard, the central member 110may assist in providing cooling for the twisted pair components 105A-Fand/or the twisted pairs contained therein. As shown in FIG. 1, incertain embodiments, a single longitudinal channel 135 may beincorporated into the central member 110; however, as explained ingreater detail below, other central member constructions may include aplurality of longitudinal channels.

As desired in various embodiments, the central member 110 may be formedin accordance with a wide variety of suitable dimensions, shapes, ordesigns. The central member 110 illustrated in FIG. 1 has anapproximately circular or rod-shaped cross-section. In otherembodiments, a central member 110 may be formed with other suitablecross-sectional shapes including, but not limited to, an ellipticalshape, a diamond shape, a hexagonal shape, an octagonal shape, a shapewith spokes extending from a central portion, a cross-sectional shapethat includes any number of suitable fins, etc. In certain embodiments,the central member 110 may include a central or body portion that ispositioned between the twisted pair components 105A-F and one or moreextensions, prongs, fins, or spokes may extend from the central portion.For example, prongs may extend from an approximately circular centralportion. As desired, any number of prongs or extensions may extend fromthe central portion. Additionally, each prong or extension may extendbetween two of the twisted pair components 105A-F or other suitablecomponents positioned adjacent to the central member 110. Further, asdiscussed in greater detail below, prongs may be formed with a widevariety of suitable materials, dimensions, constructions, and/orarrangements. A few example central members having differentcross-sections are described in greater detail below with reference toFIGS. 6A-6H

Additionally, the central member 110 (or at least a central or bodyportion) may be formed with a wide variety of suitable diameters,cross-sectional areas, and/or other dimensions. For example, a centralmember 110 having a circular cross-section may have a diameter betweenapproximately 1.8 mm and approximately 7.5 mm. As another example, acentral member 110 may have a cross-sectional area between approximately2.5 mm² and approximately 44 mm². In certain embodiments, a centralmember 110 may be sized such that it has a diameter and/orcross-sectional area that is approximately equal to that of a twistedpair component 105 or other components stranded around the centralmember 110. In the event that the central member 110 and the strandedcomponents have approximately equal sizes, a six around oneconfiguration may be incorporated into the cable 100. In other words,six components may be tightly stranded around the central member 110. Inother embodiments, the central member 110 may be sized such that it islarger or smaller than the components stranded around the central member110. With a larger central member 110, as illustrated in FIG. 3, morethan six components may be stranded around the central member 110.Indeed, the central member 110 may be formed with a wide variety ofsuitable dimensions in order to achieve a wide variety of desiredoverall cable designs and/or constructions.

A wide variety of suitable methods or techniques may be utilized asdesired in order to form a central member 110. In certain embodiments,material may be extruded through one or more dies and/or via any numberof other suitable extrusion techniques in order to obtain a desiredcross-sectional shape. In other embodiments, material may be cast ormolded into a desired shape to form the central member 110.Additionally, in certain embodiments, a central member 110 may be formedin a single pass (e.g., a single extrusion step). In other embodiments,a central member 110 may be formed via multi-step process. For example,a central member 110 may be formed with a plurality of layers. Asanother example, various components of the central member 110 (e.g., acentral portion, fins or extensions, etc.) may be formed separately andthen combined together. As desired, different manufacturing techniquesmay be utilized to form various components. For example, a centralportion of the central member 110 may be extruded or molded, and then atape may be folded around the central portion in order to formextensions or prongs.

At least one longitudinal channel 135 may extend along a longitudinallength of the central member 110, for example, from a first end of thecentral member 110 to a distal end of the central member 110.Additionally, in certain embodiments, a longitudinal channel 135 mayextend through a body portion of the central member 110. In other words,the longitudinal channel 135 may define a cavity through the centralmember 110. Accordingly, the central member 110 may have both one ormore inner surfaces that define respective cavities of longitudinalchannels and an outer surface that defines an outer periphery of thecentral member 110. The longitudinal channel 135 may facilitateconvective heat transfer along a longitudinal length of the centralmember 110 and/or cable 100. For example, as heat is generated in thecable 100 (e.g., heat in the twisted pair components 105A-F, heatdeveloped at a portion of the cable 100 situated near electronicequipment, etc.), the longitudinal channel 135 may facilitate transferof the heat to other portions of the cable 100. In other words, thelongitudinal channel 135 may promote temperature balancing within thecable 100, thereby cooling the relatively hotter portions of the cable100. As a result of this convective heat transfer, the electricalperformance of the cable 100 and/or electronic equipment associated withthe cable 100 may be improved or enhanced. In certain embodiments, suchas embodiments in which the cable 100 or certain twisted pair components105A-F are used for power over Ethernet applications, the convectiveheat transfer may facilitate increased power transmission rates.

The central member 110 illustrated in FIG. 1 has a single longitudinalchannel 135. In other embodiments, a central member 110 may be formedwith a plurality of longitudinal channels. Any suitable number oflongitudinal channels may be incorporated into a central member 110 asdesired. In the event that a plurality of longitudinal channels areutilized, in certain embodiments, each of the longitudinal channels mayhave similar dimensions (e.g., diameters, cross-sectional shapes, etc.).In other embodiments, at least two longitudinal channels may havedifferent dimensions. Additionally, as desired, any number of internalribs, dividers, spokes, or other suitable portions may separate thelongitudinal channels from one another and provide internal support forthe central member 110.

A wide variety of suitable methods or techniques may be utilized to forma longitudinal channel 135 as desired. In certain embodiments, thecentral member 110 may be extruded in a manner that facilitates theformation of one or more longitudinal channels. For example, anextrusion die utilized to form the central member 110 may alsofacilitate the formation of one or more longitudinal channels. Alongitudinal channel 135 may be formed with a wide variety of suitabledimensions. As shown, the longitudinal channel 135 has an approximatelycircular cross-sectional shape. In other embodiments, a longitudinalchannel may have an elliptical, square, rectangular, hexagonal,octagonal, or any other suitable cross-sectional shape. Additionally,the longitudinal channel 135 may have any suitable cross-sectionaldiameter and/or other dimensions (e.g., width, area, etc.) that definethe size of the channel. In certain embodiments, the longitudinalchannel 135 may have a diameter between approximately 1.0 mm andapproximately 5.5 mm. For example, the longitudinal channel 135 may havea diameter of approximately 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.25mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, a diameter incorporated in arange between any two of the above values, or a diameter incorporated ina range bounded on a minimum or maximum end by one of the above values.In other embodiments, the longitudinal channel 135 may have a widthand/or length dimension between approximately 1.5 mm and approximately5.5 mm. As other examples, a longitudinal channel 135 may have awidth/length dimension of approximately 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm,3.0 mm, 3.25 mm, 3.5 nm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, a valueincorporated in a range between any two of the above values, or a valueincorporated in a range bounded on a minimum or maximum end by one ofthe above values. In yet other embodiments, the longitudinal channel 135may have a cross-sectional area between approximately 0.8 mm² andapproximately 24 mm². For example, the longitudinal channel 135 may havea cross-sectional area or approximately 0.8 mm², 1.0 mm², 1.5 mm², 2mm², 3 mm², 4 mm², 5 mm², 6 mm², 7 mm², 8 mm², 9 mm², 10 mm², 11 mm², 12mm², 13 mm², 14 mm², 15 mm², 16 mm², 17 mm², 18 mm², 19 mm², 20 mm², 21mm², 22 mm², 23 mm², 24 mm², 25 mm², a value incorporated in a rangebetween any two of the above values, or a value incorporated in a rangebounded on a minimum or maximum end by one of the above values.Additionally, in certain embodiments, the longitudinal channel 135 (orthe combination of a plurality of longitudinal channels) may be sized inorder to achieve a desired convective heat transfer rate along the cable100.

In certain embodiments, the longitudinal channel 135 may be filled witha suitable gas, such as air, nitrogen, helium, or a suitable mixture ofgases. As desired, a gas or mixture of gases having a desired thermalconductivity, such as a thermal conductivity estimated using theChapman-Enskog model, may be selected. In other embodiments, thelongitudinal channel 135 may be filled with a suitable refrigerant orcooling liquid, such as water, glycols, one or more dielectric fluids,etc. Additionally, in certain embodiments, a substance (e.g., air, etc.)may be permitted to freely migrate within the channel. In otherembodiments, the cable 100 may be connected to one or more suitablecirculation systems that facilitate flow of a cooling substance throughthe cable 100. For example, one or more fans may be positioned at an endof the cable 100 to facilitate gas flow through the longitudinal channel135. As another example, one or more suitable pumping systems,compressors, refrigeration systems, etc. may facilitate the flow ofcooling gas and/or liquid through the longitudinal channel 135. In theevent that a plurality of longitudinal channels are incorporated into acentral member, in certain embodiments, one or more fluid diverting endcaps and/or other suitable components may be utilized to facilitate therecirculation of fluids (e.g., gases, liquids, etc.) through two or morelongitudinal channels.

In certain embodiments, the central member 110 may additionally includeone or more second channels that extend from a longitudinal channel 135through the central member 110. For example, one or more second channelsmay extend from the cavity defined by the longitudinal channel 135through a body of the central member 110 to an outer surface of thecentral member 110. These second channels may further facilitateconvective heat transfer via the central member 110. For example, one ormore second channels may facilitate transfer of heat from other areas ofthe cable core (e.g., areas in which one or more twisted pairscomponents 105A-F are positioned) to the longitudinal channel 135, andthe longitudinal channel 135 may then assist in normalizing thetemperature of the cable 100 along its longitudinal length.

A second channel may be formed with a wide variety of suitabledimensions. As desired in various embodiments, a second channel may havean approximately circular, elliptical, square, rectangular, hexagonal,octagonal, or any other suitable cross-sectional shape. Additionally,the second channel may have any suitable cross-sectional diameter and/orother dimensions (e.g., width, area, etc.) that define the size of thechannel. In certain embodiments, a second channel may have a diameter,cross-sectional area, or other dimension similar to those describedabove for the longitudinal channel 135. For example, the second channelmay have a cross-sectional area of approximately 0.5 mm², 0.8 mm², 1.0mm², 1.5 mm², 2 mm², 3 mm², 4 mm², 5 mm², 6 mm², 7 mm², 8 mm², 9 mm², 10mm², a value incorporated in a range between any two of the abovevalues, or a value incorporated in a range bounded on a minimum ormaximum end by one of the above values. Additionally, in certainembodiments, the second channel may be sized in order to achieve adesired convective heat transfer rate between the cable core and thelongitudinal channel 135.

As desired in various embodiments, any number of second channels may beincorporated into the central member 110. Additionally, a wide varietyof configurations and/or arrangements of second channels may beutilized. In certain embodiments, one or more second channels may bepositioned at a plurality of respective points along the longitudinallength of the central member 110. For example, second channels may bespaced along the central member 110 in a pattern or with a repeatingstep. A wide variety of suitable spacings or distances may be presentbetween second channels, such as spacings of approximately 0.05 meters,0.1 meters, 0.25 meters, 0.5 meters, 1.0 meters, 1.5 meters, 2.0 meters,2.5 meters, 3.0 meters, 4.0 meters, 5.0 meters, a spacing included in arange between any two of the above values, and/or a spacing that isincluded in a range bounded on either a minimum or maximum end by one ofthe above values. In other embodiments, second channels may bepositioned along the central member 110 in accordance with a random orpseudo-random pattern.

Additionally, in certain embodiments, a single second channel may beformed at each respective cross-sectional location along a longitudinallength of the central member 110. In other embodiments, a plurality ofsecond channels may be formed at one or more locations at which secondchannels are positioned. For example, a first one of the second channelsmay open at a first point along an outer periphery of the central member110 (e.g., a location proximate to a first twisted pair component) whilea second one of the second channels may open at a second point along anouter periphery of the central member 110 (e.g., a location proximate toa second twisted pair component). Any number of second channels may beformed at a given location. For example, a second channel may be formedthat corresponds to each of the twisted pairs components 105A-F. Asanother example, a second channel may be formed that corresponds to eachprong or fin extending from the central member 110.

In other embodiments, one or more second channels having a firstorientation may be formed at a first longitudinal position along thecentral member 110 while one or more additional second channels having asecond orientation may be formed at a second longitudinal position alongthe central member 110. For example, at a first position, a secondchannel may be formed that opens at a location proximate to a firsttwisted pair component and, at a second position, an additional secondchannel may be formed that opens at a location proximate to a secondtwisted pair component. As another example, second channels may beformed with different directions through the central member 110, and thedirection of the formation may be altered such that a first one of thesecond channels opens proximate to a first and fourth twisted paircomponent 105A, 105D; a second one of the second channels opensproximate to a second and fifth twisted pair component 105B, 105E; andthird one of the second channels opens proximate to a third and sixthtwisted pair component 105C, 105F. A wide variety of other suitableconfigurations may be utilized as desired, and those discussed hereinare provided by way of example only.

Further, a second channel may extend through the central member 110 atany desired angle. In certain embodiments, a second channel may beformed such that it is perpendicular to the longitudinal channel 135. Inother embodiments, a second channel may be formed such that it opensinto the longitudinal channel 135 at an acute angle. A wide variety ofsuitable acute angles may be utilized as desired, such as anapproximately 25°, 30°, 35°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°,85°, any angle included in a range between any two of the above values,and/or an angle that is included in a range bounded on either a minimumor maximum end by one of the above values. In certain embodiments, eachof the second channels may be formed at approximately equal angles withrespect to the longitudinal channel 135. In other embodiments, at leasttwo of the second channels may be formed at varying or different angleswith respect to the longitudinal channel 135.

A wide variety of suitable methods or techniques may be utilized to formone or more second channels as desired in various embodiments. Incertain embodiments, after the central member 110 is formed (e.g.,extruded, etc.), one or more suitable punching, cutting, and/or drillingdevices may be utilized to form second channels in the central member110. Each device may form respective second channels at a plurality oflocations along the central member 110 as the central member 110 is fedpast and/or through the device. In certain embodiments, the centralmember 110 may be extruded or otherwise formed, and second channels maythen be formed in a relatively continuous or on-line process. In otherembodiments, formation of the central member 110 and the second channelsmay occur in an off-line manner.

As desired in various embodiments, electromagnetic shielding materialmay be incorporated into the central member 110. A wide variety ofdifferent types of materials may be utilized to provide shielding, suchas electrically conductive material, semi-conductive material, and/ordielectric shielding material. A few examples of suitable materials aredescribed in greater detail below. Additionally, as desired in variousembodiments, shielding material may be incorporated into the centralmember 110 at a wide variety of locations. In certain embodiments,shielding material may be formed on one or more surfaces of the centralmember 110. For example, shielding material may be formed on an internalsurface of the central member 110 body within the longitudinal channel135. As another example, shielding material may be formed on an externalsurface of the central member 110, such as on an external surface of acentral member body and/or on one or more fins, prongs, or extensions.As yet another example, shielding material may be formed on a pluralityof surfaces of the central member 110, such as on an internal surfaceand on an external surface. In other embodiments, shielding material maybe embedded within the body of the central member 110. For example,particles of shielding material may be blended into or otherwiseincorporated into the body of the central member 110. As anotherexample, a layer of shielding material may be positioned between layersof a central member body, such as two dielectric layers. In yet otherembodiments, a central member 110 may be extruded, molded, or otherwiseformed from a one or more suitable shielding materials. For example, acentral member 110 may be formed from one or more conductive,semi-conductive, and/or dielectric shielding materials. In yet otherembodiments, a central member 110 may include a plurality of differenttypes of shielding materials. For example, a central member 110 may beextruded from a dielectric shielding material and one or more layers ofelectrically conductive material may be formed on the central member110. A wide variety of other suitable central member constructions thatincorporate shielding material may also be utilized.

In certain embodiments, the central member 110 may include shieldingmaterial that is continuous along the longitudinal length of the centralmember 110. For example, a relatively continuous layer of shieldingmaterial may be formed on a central member surface. As another example,the central member 110 may be formed from one or more shieldingmaterials. In other embodiments, the central member 110 may includediscontinuous shielding material. With discontinuous shielding material,shielding material may be spaced throughout the central member 110 orwithin a layer of the central member 110 (e.g., a layer formed on asurface) and gaps or spaces may be present between adjacent shieldingmaterial components. In certain embodiments, one or more discontinuouspatches of shielding material may be formed. For example, discontinuouspatches of shielding material may be formed on one or more centralmember surfaces. As described in greater detail below, a wide variety ofsuitable configurations and/or patterns of shielding material may beformed as desired in various embodiments.

As set forth above, in certain embodiments, one or more prongs,extensions, fins, or projections (hereinafter referred to as prongs) maybe incorporated into a central member 110. For example, one or moreprongs may extend from a central portion of the central member 110. Afew examples of central members that include prongs are described ingreater detail below with reference to FIGS. 2, 5F, 5G, 6E, and 6F. Incertain embodiments, a prong may extend between two components formedaround the central member 110, such as two of the twisted paircomponents 105A-F. As desired, any number of prongs may extend from thecentral member 110. For example, a respective prong may extend betweeneach pair of adjacent components formed around the central member 110.

Additionally, each prong may have a wide variety of suitable dimensionsand/or constructions. For example, a prong may have a wide variety ofsuitable lengths and/or thicknesses at any given cross-sectional pointalong a longitudinal length of the central member 110. In certainembodiments, the length of the prong may be the distance that the prongextends from a body of the central member 110 towards the jacket 115.Examples of suitable lengths include lengths of approximately 0.25, 0.5,0.75, 1.0, 1.25, and 1.5 times the diameter of a twisted pair component105, lengths included in a range between any two of the above values,and lengths included in a range bounded on either a minimum or maximumend by one of the above values. In certain embodiments, the thickness ofa prong may correspond to a dimension that defines a minimum separationbetween components (e.g., two twisted pair components, etc.) positionedon either side of the prong. Examples of suitable thicknesses include,for example, thickness that are approximately 0.25, 0.3, 0.35, 0.4,0.45, 0.5 times that of the length of a prong, thicknesses included in arange between any two of the above values, and thicknesses included in arange bounded on either a minimum or maximum end by one of the abovevalues. Further, although the example prongs illustrated in FIGS. 2, 5F,5G, 6E, and 6F are relative strait or flat projections, in otherembodiments, prongs may have other cross-sectional shapes. For example,a prong may have an approximately A-shaped, V-shaped, T-shaped,L-shaped, J-shaped, or other suitable cross-sectional shape.

In certain embodiments, a prong may be formed from the same material orgroups of materials as a body portion or central component of thecentral member 110. For example, a central member 110 may be molded orextruded to include both a body portion and one or more prongs. In otherembodiments, a prong may be formed from a different material or group ofmaterials than a body portion of the central member 110. For example, abody portion of the central member 110 may be formed from one or morepolymeric materials, and a prong may be formed from an electricallyconductive material or from a dielectric material that includeselectrically conductive patches. In this regard, the prong may provideshielding between two twisted pair components and/or may function as aheat sink that draws heat away from the twisted pair components andtransfers it to the central member 110.

Additionally, in certain embodiments, a prong may be continuous along alongitudinal length of the central member 110. In other words, the prongmay extend approximately from one end of the central member 110 to adistal end of the central member 110. In other embodiments, a prong mayselectively extend from the central member 110 at various locationsalong its longitudinal length. For example, one meter sections of prongsmay extend from the central member 110 with gaps or spaces formedbetween adjacent sections. Each prong section may have any suitablelongitudinal length, and the gaps or spaces between sections may haveany suitable longitudinal lengths. In certain embodiments, the variousprong sections may be formed in accordance with a repeating pattern ordefinite step. In other embodiments, prong sections may be formed withrandom or pseudo-random longitudinal lengths. In yet other embodiments,different longitudinally-extending sections of a prong, regardless ofwhether the prong is continuous or whether it includes gaps between aplurality of sections, may be formed from different materials and/orgroups of materials. For example, a first section may be formed from anelectrically conductive material while a second section is formed from adielectric material. As another example, a first section may be formedfrom a dielectric material while a second section is formed from a flameretardant material. Indeed, a wide variety of suitable combinations ofmaterials may be utilized.

In certain embodiments, a prong may be formed as a relatively solidstructure. In other embodiments, one or more longitudinally extendingchannels may be incorporated into a prong. These longitudinal channelsmay be similar to the longitudinal channel 135 described above for thecentral member. As desired, a prong may also include any number ofsecond channels. Additionally, in certain embodiments, channelsincorporated into a prong may be connected to or in fluid communicationwith at least one longitudinal channel formed through the body portionof the central member 110. A prong may also incorporate a wide varietyof suitable shielding material as desired in various embodiments.

As desired in various embodiments, one or more heat sinks may also beincorporated into the central member 110. A heat sink may operate toabsorb and/or transfer thermal energy or heat away from the twisted paircomponents 105A-F and/or electronic equipment associated with the cable100. In certain embodiments, a heat sink may transfer heat to thelongitudinal channel 135 such that the heat may be removed and/ordissipated. A wide variety of different types of heat sinks may beincorporated into the central member 110. Examples of suitable heatsinks include heat sinks formed from aluminum, aluminum alloys, copper,copper alloys, other metallic materials, diamond, one or more compositematerials, etc. Additionally, a heat sink may be positioned at a widevariety of locations within a central member 110. In certainembodiments, a heat sink may be positioned within a longitudinal channel135 or within a second channel. In other embodiments, a heat sink mayextend partially or completely through the central member body, forexample, from the longitudinal channel 135 through the central memberbody to an external surface. In yet other embodiments, the prongs orextensions of a central member may be formed or partially formed from oras heat sinks. As another example, heat sinks may be utilized to formfins in addition to the prongs or extensions of the central member 110,such as fins extending from an external surface of the central member110, fins extending into the longitudinal channel 135, and/or finsextending through the central member body.

A heat sink may be formed with a wide variety of suitable dimensions asdesired in various embodiments. For example, a heat sink may have a widevariety of suitable shapes (e.g., rectangular, trapezoidal, etc.) and/orsizes. Additionally, a plurality of heat sinks may be arranged into anysuitable configuration, such as a pin fin configuration, a straight finconfiguration, or a flared fin configuration. Further, as desired invarious embodiments, heat sinks may be positioned at a wide variety ofsuitable locations along a longitudinal length of the central member110. In certain embodiments, respective heat sinks or sets of heat sinksmay be positioned at spaced locations along a longitudinal length of thecentral member 110. A wide variety of suitable longitudinal spaces maybe present between heat sinks, such as spaces of approximately 0.1meters, 0.25 meters, 0.5 meters, 1.0 meters, 2.0 meters, 3.0 meters, 5.0meters, a spacing included in a range between any two of the abovevalues, or a spacing included in a range bounded on either a minimum ormaximum end by one of the above values. In other embodiments, a heatsink may be relatively continuous along a longitudinal length of thecentral member 110. For example, a fin may extend along a length of thecentral member 110.

In certain embodiments, a central member 110 may be formed from a singlesegment or portion. In other words, the central member 110 may be formedas a relatively continuous central member along a longitudinal length ofthe cable 100. In other embodiments, a central member 110 may be formedfrom a plurality of discrete or severed segments or portions. Forexample, discrete segments or portions may be positioned adjacent to oneanother along a longitudinal length of the central member 110. Incertain embodiments, gaps or spaces may be present between varioussegments or portions of the central member 110. In other embodiments, atleast a portion of the segments may be arranged in an overlappingconfiguration.

The central member 110 may have a body formed from a wide variety ofsuitable materials as desired in various embodiments. For example, thedielectric base of the central member 110 and/or various central membersegments can include paper, metals, alloys, various plastics, one ormore polymeric materials, one or more polyolefins (e.g., polyethylene,polypropylene, etc.), one or more fluoropolymers (e.g., fluorinatedethylene propylene (“FEP”), melt processable fluoropolymers, MFA, PFA,ethylene tetrafluoroethylene (“ETFE”), ethylene chlorotrifluoroethylene(“ECTFE”), etc.), one or more polyesters, polyvinyl chloride (“PVC”),one or more flame retardant olefins (e.g., flame retardant polyethylene(“FRPE”), flame retardant polypropylene (“FRPP”), a low smoke zerohalogen (“LSZH”) material, etc.), polyurethane, neoprene,cholorosulphonated polyethylene, flame retardant PVC, low temperatureoil resistant PVC, flame retardant polyurethane, flexible PVC, one ormore dielectric shielding materials (e.g., barium ferrite, etc.) or anyother suitable material or combination of materials. In certainembodiments, the central member 110 may have a relatively flexible body.As desired, the central member 110 may be filled, unfilled, foamed,un-foamed, homogeneous, or inhomogeneous and may or may not includeadditives (e.g., flame retardant and/or smoke suppressant materials).

As desired, a wide variety of suitable techniques and/or processes maybe utilized to form the central member 110 or various segments orcomponents of the central member 110. For example, a base material ordielectric material may be extruded, poltruded, or otherwise formed. Incertain embodiments, electrically conductive material or other shieldingmaterial may be applied to the base material, inserted into the basematerial, or embedded in the base material. In other embodiments,dielectric material may be formed around shielding material. As desired,the base layer may have a substantially uniform composition, may be madeof a wide range of materials, and/or may be fabricated in a singlemanufacturing pass. Further, the base layer may be foamed, may be acomposite, and may include one or more strength members, fibers,threads, or yarns. Additionally, the base layer may be hollow and/orinclude any number of longitudinal channels 135 as described above. Inother embodiments, the central member 110 or certain components of thecentral member 110 may be formed from a tape that includes one or moredielectric layers (e.g., plastic, polyester, polyethylene,polypropylene, fluorinated ethylene propylene, polytetrafluoroethylene,polyimide, or some other polymer or dielectric material that does notordinarily conduct electricity etc.) and, if desired, one or moreelectrically conductive layers (e.g., copper, aluminum, an alloy, etc.)or shielding layers. A tape utilized in a central member may be formedin a similar manner as the tape shield layer described below.

For a segmented central member formed from a plurality of discretesegments, the various portions or segments of the central member 110 mayinclude a wide variety of different lengths and/or sizes. For example, aportion of the central member 110 may be approximately 0.5 m, 1.0 m, 1.5m, 2.0 m, 2.5 m, 3.0 m, 3.5 m, a length included in a range between twoof the above values, or a length included in a range bounded on either aminimum or maximum end by one of the above values. In certainembodiments, portions having a common length may be incorporated intothe cable 100. In other embodiments, portions of the central member 110may have varying lengths. These varying lengths may follow anestablished pattern or, alternatively, may be incorporated into thecable 100 at random. Additionally, in certain embodiments, each segmentor portion of the central member 110 may be formed from similarmaterials. In other embodiments, a central member 110 may make use ofalternating materials in adjacent portions (whether or not a gap isformed between adjacent portions). For example, a first portion orsegment of the central member 110 may be formed from a first set of oneor more materials, and a second portion or segment of the central member110 may be formed from a second set of one or more materials. As oneexample, a relatively flexible material may be utilized in every otherportion of a central member 110. As another example, relativelyexpensive flame retardant material and/or shielding material may beselectively incorporated into desired portions of a central member 110.

As set forth above, the central member 110, one or more shield layers(e.g. shield layer 125, etc.), a separator (e.g., separator 130), and/orany other suitable component may provide shielding for the cable 100and/or various cable components (e.g., one or more twisted paircomponents 105A-F). Any of the components that provide shielding may begenerally referred to as a shield element. Additionally, as previouslymentioned, shielding material may be incorporated into a shield elementutilizing a wide variety of suitable techniques and/or configurations.For example, a shield element may be formed (e.g., extruded, molded,etc.) from a shielding material. As another example, shielding materialmay be embedded into a shield element. As yet another example, shieldingmaterial may be formed on a base layer or a dielectric layer. In certainembodiments, a separate base dielectric layer and shielding layer may bebonded, adhered, or otherwise joined (e.g., glued, etc.) together toform a shield element. In other embodiments, shielding material may beformed on a dielectric layer via any number of suitable techniques, suchas the application of metallic ink or paint, liquid metal deposition,vapor deposition, welding, heat fusion, adherence of patches to thedielectric, or etching of patches from a metallic sheet. In certainembodiments, the patches of shielding material can be over-coated with adielectric layer or electrically insulating film, such as a polyestercoating.

In certain embodiments, a shield element may be a relatively continuousshield element that includes shielding material that extendssubstantially along a longitudinal length of the shield element. Forexample, a relatively continuous metallic material, a braided shieldingmaterial, or a foil shield may be utilized. In other embodiments, ashield element may be formed as a discontinuous shield element having aplurality of isolated patches of shielding material. For non-segmentedor continuous shield elements, a plurality of patches of shieldingmaterial may be incorporated into the shield element, and gaps or spacesmay be present between adjacent patches in a longitudinal direction. Forsegmented shield elements, in certain embodiments, each segment orsection of the shield element may include either a single patch ofshielding material. In other embodiments, a segment of a shield elementmay include a plurality of electrically conductive patches, and gaps orspaces may be present between adjacent patches. For example, a pluralityof discontinuous patches may be formed on one or more surfaces with gapsbetween adjacent patches. A wide variety of different patch patterns maybe formed as desired in various embodiments, and a patch pattern mayinclude a period or definite step. In other embodiments, patches may beformed in a random or pseudo-random manner. Additionally, fordiscontinuous shields, individual patches may be separated from oneanother so that each patch is electrically isolated from the otherpatches. That is, the respective physical separations between thepatches may impede the flow of electricity between adjacent patches. Incertain embodiments, the physical separation of other patches may beformed by gaps or spaces, such as gaps of dielectric material or airgaps.

A wide variety of suitable materials and/or combination of materials maybe utilized to form shielding layers and/or patches of shieldingmaterial. In certain embodiments, one or more electrically conductivematerials may be utilized including, but not limited to, metallicmaterial (e.g., silver, copper, nickel, steel, iron, annealed copper,gold, aluminum, etc.), metallic alloys, conductive composite materials,etc. Indeed, suitable electrically conductive materials may include anymaterial having an electrical resistivity of less than approximately1×10⁻⁷ ohm meters at approximately 20° C. In certain embodiments, anelectrically conductive material may have an electrical resistivity ofless than approximately 3×10⁻⁸ ohm meters at approximately 20° C. Inother embodiments, one or more semi-conductive materials may be utilizedincluding, but not limited to, silicon, germanium, other elementalsemiconductors, compound semiconductors, materials embedded withconductive particles, etc. In yet other embodiments, one or moredielectric shielding materials may be utilized including, but notlimited to, barium ferrite, etc.

The components of a shield element or various segments of a shieldelement may include a wide variety of suitable dimensions, for example,any suitable lengths in the longitudinal direction and/or any suitablethicknesses. A dielectric portion included in a shield element orsegment, for example, the body portion of a central member, may have anysuitable thickness. Additionally, each patch of shielding material mayhave any desired thickness, such as a thickness of about 0.5 mils (about13 microns) or greater. In many applications, signal performancebenefits from a thickness that is greater than about 2 mils, for examplein a range of about 2.0 to about 2.5 mils, about 2.0 to about 2.25 mils,about 2.25 to about 2.5 mils, about 2.5 to about 3.0 mils, or about 2.0to about 3.0 mils.

In certain embodiments, a patch of shielding material may coversubstantially an entire area of a shield element or shield elementsegment. In other embodiments, a plurality of patches may be formed on asegment and/or a relatively continuous shield element. A wide variety ofsegment and/or patch lengths (e.g., lengths along a longitudinaldirection of the cable 100) may be utilized. As desired, the dimensionsof the segments and/or patches can be selected to provideelectromagnetic shielding over a specific band of electromagneticfrequencies or above or below a designated frequency threshold. Incertain embodiments, each segment and/or patch may have a length ofabout one meter to about one hundred meters, although lengths of lessthan one meter (e.g., lengths of about 1.5 to about 2 inches, etc.) maybe utilized. For example, the segments and/or patches may have a lengthin a range of about one to ten meters. In various embodiments, thesegments and/or patches can have a length of about 0.5, 0.75, 1.0, 1.5,2.0, 2.5, 3.0, 3.5, 4.0, 4.5, or 5.0 meters or in a range between anytwo of these values;

In the event that a plurality of patches is formed on a relativelycontinuous shield element or a shield element segment, a wide variety ofsuitable gap distances or isolation gaps may be provided betweenadjacent patches. For example, the isolation spaces can have a length ofabout 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, or 4 millimeters or in a rangebetween any two of these values. In one example embodiment, each patchmay be at least two meters in length, and a relatively small isolationgap (e.g., 4 millimeters or less, about 1/16 of an inch, etc.) may beformed between adjacent patches. As explained in greater detail belowwith reference to FIG. 7F, in certain embodiments, a plurality ofmicrocuts may be utilized to form a gap between two patches.Additionally, as desired, the patches may be formed as first patches(e.g., first patches on a first side of a dielectric material or bodyportion, on an outer surface), and second patches may be formed on anopposite side of the shield element (e.g., on an opposite side of adielectric material or body portion, within a longitudinal channel,etc.). For example, second patches may be formed to correspond with thegaps or isolation spaces between the first patches. As desired, thepatches may have a wide variety of different shapes and/or orientations.For example, the patches may have a rectangular, trapezoidal, orparallelogram shape. A few example shapes for patches are described ingreater detail below with reference to FIGS. 7A-7G.

In certain embodiments, shield element segments and/or patches may beformed to be approximately perpendicular (e.g., square or rectangularsegments and/or patches) to the longitudinal axis of twisted pairsincorporated into the cable 100 (e.g., pairs enclosed by a shield, pairsadjacent to a separator, etc.). In other embodiments, the segmentsand/or patches may have a spiral direction that is opposite the twistdirection of one or more pairs. That is, if the twisted pair(s) aretwisted in a clockwise direction, then the segments and/or patches mayspiral in a counterclockwise direction. If the twisted pair(s) aretwisted in a counterclockwise direction, then the conductive patches mayspiral in a clockwise direction. Thus, twisted pair lay opposes thedirection of the segment and/or patch spiral. The opposite directionsmay provide an enhanced level of shielding performance. In otherembodiments, the segments and/or patches may have a spiral directionthat is the same as the twist direction of one or more pairs.

According to an aspect of the disclosure, one or more techniques may beutilized to reduce and/or eliminate electrical perturbations betweenshielding patches and/or at the circumferential edges of a shieldelement. As desired, these techniques may be applied to shield layers(e.g., the external shield 125, etc.), separators (e.g., separator 130,etc.), a central member 110, and/or to other suitable shield elements.As one example technique, in certain embodiments, at least one patchincluded in a shield element may be electrically shorted to itself orelectrically continuous along a circumferential direction of the shieldelement. As another example technique, a shield element may be formedwith overlapping segments in order to effectively eliminate longitudinalspaces or gaps between adjacent patches formed on the shield element.Each of these techniques are described in greater detail below.

In certain embodiments, at least one patch included in a shield elementmay be electrically shorted or continuous along a circumferentialdirection. For example, when a shield 125 (or a plurality of shieldsegments) is wrapped around one or more twisted pairs 105A-D, a patchmay contact itself at or near the edges of the shield 150. As anotherexample, when a separator 130 is formed from a tape, a patch may contactitself at or near the edges of the tape. As yet another example, a patchmay be formed on a central member 110 or separator 130 such that thepatch extends around the circumference of the shield element andcontacts itself. In any of these examples, the patch may be electricallyshorted to itself, thereby creating a continuous patch in acircumferential direction or along a periphery of the shield element.When the shield element is formed to include a plurality of patches thatare discontinuous in a longitudinal direction and one or more patchesare electrically shorted in a circumferential direction, electricalperturbations caused by the shield element may be reduced relative toconventional cables. Therefore, the cable 100 may exhibit improvedelectrical performance, such as reduced return loss and/or reducedcross-talk loss.

In certain embodiments, at least one shield element may be formed toinclude overlapping segments. For example, a shield element may beformed to include a plurality of electrically conductive patchesarranged in a discontinuous manner; however, in contrast to certainconventional shield elements, the shield element may not include spacesor gaps between certain patches along its longitudinal direction. Theshield element may include a plurality of discrete overlapping segmentsor sections along a longitudinal length of the cable, and each segmentmay include at least one patch of shielding material. The combination ofthe segments may form a discontinuous shield element; however, theoverlapping nature of the segments may eliminate gaps between certainpatches along a longitudinal direction. Thus, the discontinuous shieldelement may exhibit improved electrical performance relative toconventional discontinuous shields.

The jacket 115 may enclose the internal components of the cable 100,seal the cable 100 from the environment, and provide strength andstructural support. The jacket 115 may be formed from a wide variety ofsuitable materials and/or combinations of materials, such as one or morepolymeric materials, one or more polyolefins (e.g., polyethylene,polypropylene, etc.), one or more fluoropolymers (e.g., fluorinatedethylene propylene (“FEP”), melt processable fluoropolymers, MFA, PFA,ethylene tetrafluoroethylene (“ETFE”), ethylene chlorotrifluoroethylene(“ECTFE”), etc.), one or more polyesters, polyvinyl chloride (“PVC”),one or more flame retardant olefins (e.g., flame retardant polyethylene(“FRPE”), flame retardant polypropylene (“FRPP”), a low smoke zerohalogen (“LSZH”) material, etc.), polyurethane, neoprene,cholorosulphonated polyethylene, flame retardant PVC, low temperatureoil resistant PVC, flame retardant polyurethane, flexible PVC, or acombination of any of the above materials. The jacket 115 may be formedas a single layer or, alternatively, as multiple layers. In certainembodiments, the jacket 115 may be formed from one or more layers offoamed material. As desired, the jacket 115 can include flame retardantand/or smoke suppressant materials. Additionally, the jacket 115 mayinclude a wide variety of suitable shapes and/or dimensions. Forexample, the jacket 115 may be formed to result in a round cable or acable having an approximately circular cross-section; however, thejacket 115 and internal components may be formed to result in otherdesired shapes, such as an elliptical, oval, or rectangular shape. Thejacket 115 may also have a wide variety of dimensions, such as anysuitable or desirable outer diameter and/or any suitable or desirablewall thickness. In various embodiments, the jacket 115 can becharacterized as an outer jacket, an outer sheath, a casing, acircumferential cover, or a shell.

An opening enclosed by the jacket 115 may be referred to as a cablecore, and the central member 110 and twisted pair components 105A-F maybe disposed within the cable core. Although a single cable core isillustrated in FIG. 1, a cable may be formed to include multiple cablecores. In certain embodiments, a cable core may be filled with a gassuch as air (as illustrated) or alternatively a gel, solid, powder,moisture absorbing material, water-swellable substance, dry fillingcompound, or foam material, for example in interstitial spaces betweenthe internal components. Other elements can be added to the cable coreas desired, for example one or more optical fibers, additionalelectrical conductors, additional twisted pairs, water absorbingmaterials, and/or strength members, depending upon application goals.

As desired in various embodiments, a wide variety of other materials maybe incorporated into the cable 100. For example, as set forth above, thecable 100 may include any number of conductors, twisted pairs, opticalfibers, and/or other transmission media. For example, as illustrated inFIG. 3, a wide variety of optical fiber components, other transmissionmedia, and/or spacers may be positioned around a central member. Asanother example, the cable 100 may include a suitable armor layer, suchas a corrugated armor or dielectric armor layer. Additionally, asdesired, a cable may include a wide variety of strength members,swellable materials (e.g., aramid yarns, blown swellable fibers, etc.),insulating materials, dielectric materials, flame retardants, flamesuppressants or extinguishants, gels, and/or other materials. The cable100 illustrated in FIG. 1 is provided by way of example only.Embodiments of the disclosure contemplate a wide variety of other cablesand cable constructions. These other cables may include more or lesscomponents than the cable 100 illustrated in FIG. 1. Additionally,certain components may have different dimensions and/or materials thanthe components illustrated in FIG. 1.

FIG. 2 is a cross-sectional view of another example cable 200 that mayinclude a central member that provides for convective heat transfer,according to an illustrative embodiment of the disclosure. The cable 200of FIG. 2 may include components that are similar to the cable 100illustrated and described above with reference to FIG. 1. Accordingly,the cable 200 may include a plurality of twisted pair components 205A-Fdisposed in a cable core and stranded around a central member 210. Anouter jacket 215 may enclose the internal components of the cable 200.

The central member 210 illustrated in FIG. 2 has a differentcross-sectional shape than the central member 110 of FIG. 1. Morespecifically, the central member 210 includes a plurality of prongs,projections, or fins 220 extending from a body portion of the centralmember 210. As shown, a respective prong extends between each adjacentpair of twisted pair components 205A-F; however, in other embodiments,other numbers of prongs may be utilized. Additionally, each prong may beformed with a wide variety of suitable dimensions, such as a widevariety of suitable cross-sectional shapes, lengths, and/or thicknesses.

The central member 210 of FIG. 2 is also illustrated as including aplurality of longitudinal channels 225A, 225B. Additionally, an internalspline, rib or support 230 may be positioned between the longitudinalchannels 225A, 225B. As desired in various embodiments, the centralmember 210 may include any number of longitudinal channels.Additionally, a wide variety of suitable internal structures including,but not limited to, extruded material, ribs, splines, etc., may beincorporated into the central member 210.

Additionally, for the twisted pair components 205A-F illustrated in FIG.2, each of the twisted pairs may be individually shielded. For example,instead of including an overall shield formed around the plurality oftwisted pairs, shield layers may respectively be wrapped or otherwiseformed around each of the twisted pairs. In other embodiments, a portionor none of the twisted pairs may be individually shielded. As desired,an overall shield may be formed around any number of individuallyshielded twisted pairs. Indeed, a wide variety of different shieldingarrangements may be utilized in accordance with various embodiments ofthe disclosure.

FIG. 3 is a cross-sectional view of another example cable 300 includinga central member with at least one longitudinal channel that facilitatesconvective heat transfer, according to an illustrative embodiment of thedisclosure. The cable 300 of FIG. 3 may include components that aresimilar to the cables 100, 200 illustrated and described above withreference to FIGS. 1 and 2. Accordingly, the cable 300 may include aplurality of twisted pair components 305A-D disposed in a cable core,and stranded around a central member 310. An outer jacket 315 mayenclose the internal components of the cable 300.

The central member 310 of FIG. 3 may be similar to the central member110 of FIG. 1; however, the central member 310 of FIG. 3 may have alarger diameter and/or cross-sectional area than the central member 110of FIG. 1. In FIG. 1, the central member 110 is sized to beapproximately equal to the twisted pairs components 105A-F and,therefore, a six around one construction is formed. The central member310 of FIG. 3 may be larger than the twisted pair components 305A-D.Accordingly, more than six components may be stranded or otherwiseformed around the central member 310. As shown, eight components areformed around the central member 310; however, any other embodiments,any desired number of components may be formed around a central member.

The twisted pair components 305A-D of FIG. 3 may be similar to thosedescribed above with reference to FIG. 1. However, only four twistedpair components are illustrated in FIG. 3. The cable 300 additionalincludes a plurality of other components formed around the centralmember 310. As desired, any number of and/or a wide variety of varioustypes of components may be incorporated into a cable. For example, oneor more optical fiber components, coaxial cable components, powerconductors, and/or other transmission media may be incorporated into acable. As shown in FIG. 3, a plurality of optical fiber components 320,325, 330 are formed around the central member 310. For example, anoptical fiber component 320 that includes one or more tight bufferedoptical fibers encased in a suitable buffer tube, jacket layer, strengthlayer, and/or other covering may be incorporated into the cable 300. Asanother example, an optical fiber component 325 that includes aplurality of optical fibers incorporated into one or more loose buffertubes, microtubes and/or other sheaths may be incorporated into thecable 300. As yet another example, an optical fiber component 330 thatincludes one or more optical fiber ribbons encased in a suitable buffertube, jacket layer, strength layer, and/or other covering may beincorporated into the cable 300. Additionally, in certain embodiments,one or more spacing elements 335 and/or strength members (e.g., strengthrods, etc.) may be incorporated into the cable 300 in place oftransmission media in order to provide the cable 300 with a desiredcross-sectional profile.

Similar to the cable 100 illustrated in FIG. 1, the cables 200, 300illustrated in FIGS. 2 and 3 are provided by way of example only.Embodiments of the disclosure contemplate a wide variety of other cablesand cable constructions. These other cables may include more or lesscomponents than the cables 200, 300 illustrated in FIGS. 2 and 3. Forexample, other cables may include alternative shielding arrangementsand/or different types of central members. Additionally, certaincomponents may have different dimensions and/or materials than thecomponents illustrated in FIGS. 2 and 3.

Example Twisted Pair Component Constructions

A few example twisted pair components are illustrated and describedabove with reference to FIGS. 1-3. In particular, FIGS. 1 and 3illustrate twisted pair components that include a cross-shaped separatorpositioned between a plurality of twisted pairs and an overall shieldformed around the twisted pairs and the separator. FIG. 2 illustrates atwisted pair component that includes individually shielded twisted pairsand an optional binder that holds the pairs together. In otherembodiments, a wide variety of other suitable twisted pair componentconstructions may be utilized. A few non-limiting examples of twistedpair components are illustrated in FIGS. 4A-4D. Any of these twistedpair components, as well as other types of components, may beincorporated into a cable that includes a central member that provides acooling function.

Turning first to FIG. 4A, an example twisted pair component 400 isillustrated that includes a plurality of twisted pairs 405A-D with aseparator 410 having an approximately X-shaped cross-sectionalpositioned between the twisted pairs 405A-D. Additionally, an overallshield layer 415 is formed around the twisted pairs 405A-D and theseparator 410. In this regard, the twisted pair component 400 may besimilar to the components 105A-F, 305A-D described above with referenceto FIGS. 1 and 3. However, in contrast to the components illustrated inFIGS. 1 and 3, the separator 410 of the twisted pair component 400 isillustrated as including a longitudinal channel 420 that may provide forconvective heat transfer that assists in cooling and/or normalizing thetemperature within the twisted pair component 400. As desired in variousembodiments, the separator 410 may include a wide variety of othercomponents, such as second channels, shielding material, and/or heatsinks.

FIG. 4B illustrates another example twisted pair component 425 thatincludes a plurality of twisted pairs 430A-D. Additionally, the twistedpair component 425 may include a separator 435 formed between at leasttwo of the twisted pairs 430A-D. For example, the twisted pair component425 may include a relatively flat separator 435 that approximatelybisects the core of the twisted pair component 425 such that two pairsare positioned on either side of the separator 435. In variousembodiments, the separator 435 may include one or more longitudinalchannels, one or more second channels, shielding material, heat sinks,and/or a wide variety of other suitable components.

With continued reference to FIG. 4B, individual shield layers 440A-D maybe respectively formed around each of the twisted pairs 430A-D. Forexample, a first shield layer 440A may be formed around a first twistedpair 430A; a second shield layer 440B may be formed around a secondtwisted pair 430B; a third shield layer 440C may be formed around athird twisted pair 430C; and a fourth shield layer 440D may be formedaround a fourth twisted pair 430D. Additionally, in certain embodiments,an overall shield 445 may be formed around the individually shieldedtwisted pairs 430A-D and the separator 435. Indeed, as described ingreater detail above, a twisted pair component may be formed with a widevariety of suitable shielding arrangement.

In certain embodiments, respective dielectric separators 450A-D may bewoven helically between the individual conductors or conductive elementsof one or more of the twisted pairs 430A-D. In other words, a dielectricseparator (generally referred to as dielectric separator 450) may behelically twisted with the conductors of a twisted pair 430 along alongitudinal length of the twisted pair component 425. In certainembodiments, the dielectric separator 450 may maintain spacing betweenthe individual conductors of the twisted pair 430 and/or maintain thepositions of one or both of the individual conductors. For example, thedielectric separator 450 may be formed with a cross-section (e.g., anX-shaped cross-section, an H-shaped cross-section, etc.) that assists inmaintaining the position(s) of one or both the individual conductors ofthe twisted pair 430. In other words, the dielectric separator 450 mayreduce or limit the ability of one or both of the individual conductorsto shift, slide, or otherwise move in the event that certain forces,such as compressive forces, are exerted on the twisted pair component425. As illustrated in FIG. 4B, a dielectric separator 235 may be formedas a relatively simple film layer that is positioned between theindividual conductors of a twisted pair 430.

FIG. 4C illustrates another example twisted pair component 455 thatincludes a plurality of twisted pairs 460A-D. In certain embodiments,the twisted pair component 455 may include a separator 465 formedbetween at least two of the twisted pairs 460A-D. The separator 465illustrated in FIG. 4C has a different construction than the separators410, 435 illustrated in FIGS. 4A and 4B. In particular, the separator465 is a generally T-shaped separator that approximately bisects (orotherwise divides) the cable core and forms two channels along alongitudinal length of the twisted pair component 455. In one exampleembodiment, two twisted pairs 460A, 460B can be disposed in a firstchannel and the remaining two twisted pairs 460C, 460D can be disposedin a second channel. The separator 465 further includes one or moreprongs formed at or near one end of the separator 465. The prong(s) mayassist in anchoring the separator 465 to an outer shield layer 470 (orother layer that surrounds the core of the twisted pair component 455),thereby limiting movement of the separator 465. Additionally, in variousembodiments, the separator 465 may include one or more longitudinalchannels, one or more second channels, shielding material, heat sinks,and/or a wide variety of other suitable components.

With continued reference to FIG. 4C, any number of shield layers may beutilized to provide shielding for the twisted pairs 460A-D. For example,a first shield layer 475A may be wrapped or otherwise formed around twoof the twisted pairs, such as the twisted pairs 460A, 460B disposed inthe first channel. A second shield layer 475B may be wrapped orotherwise formed around other twisted pairs, such as twisted pairs 460C,460D disposed in the second channel. In other words, shield layers maybe provided for various groups of twisted pairs. Additionally, incertain embodiments, an overall shield 470 may be formed around thecomponents incorporated into the core of the twisted pair component 455.

Additionally, respective dielectric separators 478A-D having an H-shapedcross-section are illustrated in FIG. 4C as being disposed or positionedbetween the individual conductors of the various twisted pairs 460A-D.As described in greater detail above with reference to FIG. 4B, thesedielectric separators 478A-D may assist in maintaining the position(s)of one or both the individual conductors of the twisted pairs 460A-D.

FIG. 4D illustrates another example twisted pair component 480 thatincludes a plurality of twisted pairs 485A-D. As shown, no separator ispositioned between any of the twisted pairs 485A-D. Additionally, eachof the twisted pairs (generally referred to as twisted pair 485)includes a respective component 490 that acts as both a dielectricseparator and as an individual shield for the twisted pair 485. Thecomponent 490 may include a first portion that is positioned between theindividual conductors of the twisted pair and/or one or more secondportions that include shielding material and that are wrapped around anouter periphery of the twisted pair 485. As shown, respective secondportions extend from either end of the first portion, and each of thesecond portions is wrapped partially around the outer periphery of thetwisted pair 485 until they contact one another, thereby forming ashield layer. In other embodiments, a single second portion may extendfrom one end of the first portion, and the second portion may be wrappedaround the entire outer periphery of the twisted pair 485. Additionally,although the first portion is illustrated as a relatively flat tape thatis positioned between the conductors, in other embodiments, a firstportion may be formed with other dimensions. For example, a firstportion may have an H-shape or other suitable cross-sectional shape.Indeed, a wide variety of configurations may be utilized as desired fora composite component that functions as both a dielectric separator anda shield.

The twisted pair components 400, 425, 455, 480 illustrated in FIGS.4A-D, as well as the twisted pair components illustrated in FIGS. 1-3,are provided by way of example only. Embodiments of the disclosurecontemplate a wide variety of other twisted pair componentconstructions. These other twisted pair components may include more orless components than the twisted pair components illustrated in FIGS.1-4D. For example, other cables may include alternative shieldingarrangements and/or different types of separators. Additionally, certaincomponents may have different dimensions and/or materials than thecomponents illustrated in FIGS. 1-4D.

Example Central Member Constructions

As set forth above, a central member, such as the central member 110illustrated in FIG. 1, may be formed with a wide variety of suitableconstructions, cross-sectional shapes, and/or dimensions. FIGS. 5A-5Iare perspective views of example central member constructions, and theexample constructions illustrate a few of the different features thatmay be incorporated into central members. Similar to the central member100 shown in FIG. 1, the central member of FIGS. 5A-5I may have agenerally rod-shaped or circular cross-section or body portion with anynumber of optional prongs or fins extending therefrom. As desired inother embodiments, a wide variety of other cross-sectional shapes may beutilized, such as any of the cross-sectional shapes illustrated in FIGS.6A-6H. Additionally, in accordance with an aspect of the disclosure,each of the example central members may include one or more longitudinalchannels. Further, any of the example central members may beincorporated into a wide variety of cables, such as the cables 100, 200,300 illustrated in FIGS. 1-3. In other words, any of the central membersillustrated in FIGS. 5A-6H may be substituted into the cables 100, 200,300 discussed above and/or incorporated into any other suitable cabledesigns.

Turning first to FIG. 5A, a perspective view of a first example centralmember 500 is illustrated. The central member 500 may be formed with anydesired shape, size, diameter, cross-sectional area, and/or otherdimensions. Additionally, the central member 500 may include at leastone longitudinal channel 505 that facilitates convective heat transferalong a longitudinal length of the central member 500. As describedabove with reference to FIG. 1, any number of longitudinal channels maybe incorporated into the central member 500, and each longitudinalchannel may have any desired shape, size, and/or other dimensions.Further the longitudinal channel 505 may define an internal cavitythrough the body of the central member 500.

FIG. 5B illustrates another example central member 510 that includes atleast one longitudinal channel 512. Additionally, the central member 510may include a plurality of second channels 514. Each second channel 514may extend from the longitudinal channel 512 through the body of thecentral member 510 and to an external surface of the central member 510.In this regard, each second channel 514 may permit the flow of air orother fluid between the longitudinal channel 512 and portions of thecore of a cable into which the central member 510 is positioned. As aresult, overall convective heat transfer rate of the central member 510may be enhanced. For example, heat may pass from outside of the centralmember 510 (e.g., from one or more twisted pair components, etc.) to thelongitudinal channel 512 via one or more second channels 514, and thelongitudinal channel 512 may facilitate heat transfer/cooling along alongitudinal length of the central member 500 and/or cable in which thecentral member 510 is incorporated.

As set forth in greater detail above with reference to FIG. 1, each ofthe second channels 514 may have any suitable shape (e.g., circular,elliptical, etc.), size (e.g., diameter, etc.), and/or other dimensions.Each second channel 514 may also be formed at any desired angle relativeto the longitudinal channel 512 (e.g., a ninety degree angle, an acuteangle, etc.). Additionally, any number of second channels 514 may beincorporated into the central member 510. A wide variety ofconfigurations and/or arrangements of second channels may be utilized.In certain embodiments, one or more second channels may be positioned ata plurality of respective points along the longitudinal length of thecentral member. For example, second channels 514 may be spaced along thecentral member 510 in a pattern or with a repeating step. A wide varietyof suitable spacings or distances “L” may be present between secondchannels, such as spacings of approximately 0.05 meters, 0.1 meters,0.25 meters, 0.5 meters, 1.0 meters, 1.5 meters, 2.0 meters, 2.5 meters,3.0 meters, 4.0 meters, 5.0 meters, a spacing included in a rangebetween any two of the above values, and/or a spacing that is includedin a range bounded on either a minimum or maximum end by one of theabove values. In other embodiments, second channels 514 may bepositioned along the central member 510 in accordance with a random orpseudo-random pattern.

In certain embodiments, a single second channel may be formed at eachrespective cross-sectional location along a longitudinal length of acentral member. In other embodiments, as illustrated by the centralmember 515 of FIG. 5C, a plurality of second channels may be formed atone or more cross-sectional locations at which second channels arepositioned. For example, a first one of the second channels 517 may openat a first point along an outer periphery of the central member 515(e.g., a location proximate to a first twisted pair component) while asecond one of the second channels 519 may open at a second point alongan outer periphery of the central member 515 (e.g., a location proximateto a second twisted pair component). Any number of second channels maybe formed at a given location. For example, a second channel may beformed that corresponds to each of the twisted pair components. Asanother example, a second channel may be formed that corresponds to eachprong or extension of a central member.

In other embodiments, one or more second channels having a firstorientation may be formed at a first longitudinal position along acentral member while one or more additional second channels having asecond orientation may be formed at a second longitudinal position alongthe central member. For example, at a first position, a second channelmay be formed that opens at a location proximate to a first twisted paircomponent and, at a second position, an additional second channel may beformed that opens at a location proximate to a second twisted paircomponent. As another example, second channels may be formed completelythrough a central member, and the direction of the formation may bealtered such that a first one of the second channels opens proximate toa first set of twisted pair components, while a second one of the secondchannels opens proximate to a second set of twisted pair components, andso on. A wide variety of other suitable configurations may be utilizedas desired, and those discussed herein are provided by way of exampleonly.

A wide variety of suitable methods and/or techniques may be utilized toform second channels, such as the second channels 514, 517, 519illustrated in FIGS. 5B and 5C. In certain embodiments, one or moresuitable punches, drills, blades, laser, or other suitable cutting toolsmay be utilized to form second channels either partially or completelythrough the body of a central member. For example, a channel may beformed from an external surface of a central member through the body toa longitudinal channel. In this regard, a single second channel may beformed. As another example, a channel may be formed completely through acentral member such that it passes through a longitudinal channel. Inthis regard, two second channels may be formed. In certain embodiments,a central member may be passed through or near the cutting tool(s) suchthat second channels may be formed at various locations along thelongitudinal length of the central member. As desired, a first set ofone or more cutting tools may be utilized to form second channels havinga first orientation, and a second set of one or more cutting tools maybe utilized to form second channels having a second orientation, and soon. Any number of cutting tools and/or sets of cutting tools may beutilized in various embodiments in order to form a central member with adesired configuration of second channels.

With continued reference to FIG. 5C, a central member 515 may be formedthat includes a plurality of longitudinal channels, such as longitudinalchannels 520, 522. Each of the longitudinal channels 520, 522 may beformed with any desirable cross-sectional shapes and/or dimensions.Additionally, as desired, any number of ribs, internal supports, spokes,and/or sections of a body portion of the central member 515 may separatethe longitudinal channels 520, 522 from one another. In certainembodiments, a plurality of longitudinal channels 520, 522 may beisolated from one another. In other words, fluid positioned in a firstlongitudinal channel 520 may not be permitted to migrate into a secondlongitudinal channel 522. In other embodiments, two or more longitudinalchannels 520, 522 may be in fluid communication with one another. Forexample, one or more channels or passageways may be formed between thelongitudinal channels 520, 522. As another example, two or morelongitudinal channels 520, 522 may be connected at one or more ends ofthe central member 515 such that fluid may be recirculated through thechannels 520, 522.

FIG. 5D illustrates another example central member 525 that mayfacilitate convective heat transfer along its longitudinal length. Muchlike the central members 500, 510, 515 of FIG. 5A-C, the central member525 of FIG. 5D may include one or more longitudinal channels, such asthe illustrated longitudinal channel 527. Additionally, the centralmember 525 may include shielding material that provides electromagneticshielding for the twisted pair components and/or other transmissionmedia incorporated into a cable. As shown, the central member 525 mayinclude first shielding material 530 formed on its external surface andsecond shielding material 532 formed inside the longitudinal channel527, for example, on a surface that defines the longitudinal channel527.

As set forth above with reference to FIG. 1, a wide variety of suitabletypes of shielding material may be utilized, such as electricallyconductive material (e.g., aluminum, etc.). Additionally, shieldingmaterial may be formed in accordance with a wide variety of suitableconfigurations. For example, in certain embodiments, relativelycontinuous shielding material may be formed along a longitudinal lengthof the central member 525. In other embodiments, discontinuous patchesof shielding material may be formed, and dielectric spaces or gaps maybe present between adjacent patches. A wide variety of suitable patternsof shielding material may be utilized as desired, and a few examplepatterns are described in greater detail below with reference to FIGS.7A-7G. These patterns may include a wide variety of patch sizes and/ordimensions, as well as a wide variety of suitable gap sizes betweenpatches. Additionally, in certain embodiments, discontinuous patches ofshielding material may be formed in a random or pseudo-random manner.

Additionally, a wide variety of different relationships may existbetween the shielding material 530 formed on an external surface of thecentral member 525 and the shielding material 532 formed inside thelongitudinal channel 527. For example, in certain embodiments, a similarpattern may be formed on the external surface and within thelongitudinal channel 527. In other embodiments, the patches of shieldingmaterial 532 formed within the longitudinal channel 527 may correspondto or cover gaps or spaces between adjacent patches of shieldingmaterial 530 formed on the external surface and vice versa. In yet otherembodiments, a first patch pattern may be utilized on the externalsurface while a second patch pattern is utilized within the longitudinalchannel 527. In yet other embodiments, a first pattern may be utilizedon the external surface, and a random or pseudo-random patchconfiguration may be utilized within the longitudinal channel 527. Inyet other embodiments, a first pattern may be utilized on the externalsurface, and a continuous layer of shielding material may be formedwithin the longitudinal channel 527 or vice versa. Indeed, a widevariety of different patterns and/or shielding configurations may beincorporated into the central member 525.

A wide variety of suitable methods or techniques may be utilized to formshielding material on both the external surface of the central member525 and/or within the longitudinal channel 527. For example, once thecentral member 525 has been formed (e.g., extruded, molded, etc.),shielding material may be deposited on, adhered to, or otherwise formedon or attached to the central member 525. Examples of suitable methodsfor forming shielding material include, but are not limited to,application of metallic ink or paint, liquid metal deposition, vapordeposition, welding, heat fusion, adherence of patches to thedielectric, and/or etching of patches from a metallic sheet.

Although each patch of shielding material formed on an external surfaceof the central member 525 is illustrated as being formed around an outerperiphery of the central member 525, other embodiments may be formedwith different configurations. For example, in certain embodiments, apatch formed on the external surface may only extend partially aroundthe outer periphery of the central member 525. In certain exampleembodiments, a patch may extend approximately 16%, 20%, 25%, 33%, 40%,50%, 66%, 75%, or any other suitable percentage around an outerperiphery of the central member 525. In certain embodiments, each patchmay cover a portion of the central member 525 that is proximate to oneof the twisted pair components. As desired in various embodiments, apatch may cover any desired portion of the surface of a central member525 and/or may extend any desired amount around an outer periphery ofthe central member 525 and/or any prongs.

Additionally, in certain embodiments, patches of shielding material maybe alternated between various portions of the central member 525 alongits longitudinal length. In certain embodiments, patches may be formeddiagonally across from each other at any given longitudinal location,and a patch pattern may be alternated along the central member'slongitudinal length. For example, given the cable constructionillustrated in FIG. 1, first patches may be formed proximate to a firstand fourth twisted pair component 105A, 105D; second patches may beformed proximate to a second and fifth twisted pair component 105B,105E; and third patches may be formed proximate to a third and sixthtwisted pair component 105C, 105F. A wide variety of other suitablepatch configurations may be formed as desired in various embodiments.For example, patches may be alternated between individual quadrants,sextants, or other sections of a central member along its longitudinallength. As another example, patches may be altered between a top halfand a bottom half of a central member along its longitudinal length. Thepatch configurations discussed herein are provided by way ofnon-limiting example only. Further, a wide variety of suitable patchconfigurations may be formed within a longitudinal channel 527 of thecentral member 525.

FIG. 5E illustrates another example central member 535 that may beutilized in various embodiments of the disclosure. In contrast tocentral members having shielding material formed on one or moresurfaces, the central member 535 of FIG. 5E may include a body portion(and optionally other portions such as prongs or fins) that is at leastpartially formed from a shielding material. Additionally, the centralmember 535 may include any number of longitudinal channels and, asdesired in various embodiments, any number of secondary channels.

A wide variety of suitable shielding materials may be incorporated intothe central member 535 as desired in various embodiments. In certainembodiments, the central member 535 may be formed (e.g., extruded,molded, etc.) from a suitable shielding material. Examples of suitablematerials that may be utilized to form the central member 535 include,but are not limited to, one or more metallic materials (e.g., silver,copper, nickel, steel, iron, annealed copper, gold, aluminum, etc.),metallic alloys, conductive composite materials, semi-conductivematerials (e.g., silicon, etc.), and/or dielectric shielding materials(e.g., barium ferrite, etc.). In other embodiments, shielding materialmay be mixed or blended into a suitable base material (e.g., a polymericmaterial, etc.) that is utilized to form the central member 535. In yetother embodiments, shielding material may be embedded in a base materialor suspended within a matrix of base material.

Turning now to FIG. 5F, another example central member 540 constructionis illustrated. The central member 540 may include a central portion 542that includes a longitudinal channel 543, and any number of prongs,fins, extensions, or projections 544 may extend from the central portion542. As shown, the central member 540 may include six prongs 544A-F, andeach prong may respectively extend between two of the twisted pairscomponents formed around the central member 540. Additionally, asdesired in various embodiments, the central member 540 may include anynumber of second channels and/or a wide variety of suitable shieldingmaterial may be incorporated into the central member 540.

In certain embodiments, the central portion 542 and the prongs 544A-Fmay be formed from the same material or group of materials. For example,the central member 540 and its various components may be extruded orotherwise formed as a unitary structure. In other embodiments, thecentral portion 542 and one or more prongs 544A-F may be formed fromdifferent materials or groups of materials. For example, the centralportion 542 may be formed from a polymeric material, and one or moreprongs 544A-F may be formed from and/or may include suitable shieldingmaterial. For example, a prong (generally referred to as prong 544) maybe formed (e.g., molded, case, extruded, etc.) from a suitable shieldingmaterial. As another example, shielding material may be mixed into,blended into, or embedded within a base material to form a prong 544. Asyet another example, shielding material may be formed on the surface ofa prong 544. As set forth above, a wide variety of suitable shieldingmaterials may be utilized.

In the event that a prong 544 is formed from different materials orincludes a different base material than the central portion 542, a widevariety of suitable techniques may be utilized to attach the prong 544to the central portion 542. For example, the prong 544 may extendthrough the central portion 542 into a longitudinal channel 543. Asdesired, an end of the prong 544 positioned within the longitudinalchannel 543 may be processed (e.g., folded over, widened, etc.) suchthat the prong 544 is held in place. In other embodiments, a singleprong 544 may extend through the longitudinal channel such that itextends from opposite sides of the central portion 542. As desired invarious embodiments, a prong 544 may be adhered, welded, or otherwiseattached or affixed to the central portion 542.

In certain embodiments, such as embodiments in which a prong 544 isformed from a shielding material, a prong 544 may function as a heatsink that pulls or draws heat into a longitudinal channel 543. In thisregard, the prong 544 may assist in cooling a cable and/or normalizing atemperature within the cable. Additionally, in certain embodiments, aprong 544 may be completely formed from or may include continuousshielding or heat sink material along a longitudinal length of thecentral member 540. In other embodiments, one or more respectiveportions positioned along a longitudinal length of a prong 544 mayinclude shielding and/or heat sink material. For example, a prong 544may be formed from alternating metallic and dielectric portions. Asdesired, various sections of a prong 544 may have any suitablelongitudinal lengths and/or other dimensions. Further, sections may bearranged in accordance with a wide variety of suitable patterns or,alternatively, sections may be arranged in a random or pseudo-randommanner. A few of the examples discussed herein with respect to patchconfigurations may be equally applicable to prong construction.

The example central member illustrated in FIG. 5F illustrates secondchannels that are formed through portions of the central member 540other than the extensions or prongs. In other words, second channels maybe formed through central members such that they open in proximity totwisted pair components positioned adjacent to the central member. Inother embodiments, second channels may be formed through other portionsof a central member. For example, second channels may be formed throughone or more of the prongs of a central member. In certain embodiments, asecond channel may be formed from the longitudinal channel through aprong such that it opens at the distal end of the prong. In otherembodiments, a second channel may be formed at an angle through a prongor, alternatively, a second channel may curve, bend, or change directionwithin a prong. In this regard, the second channel may open along asurface of the prong that faces at least one twisted pair component.

FIG. 5G illustrates another example central member 550 in which one ormore prongs are attached to a central portion 552. However, in contrastto the central member 540 of FIG. 5F, each of the prongs in FIG. 5G doesnot extend along a continuous longitudinal length of the central member550. In other words, a first set of prongs 554A-F may be formed at afirst location along a longitudinal length of the central member 550, asecond set of prongs 556A-F may be formed at a second location along thelongitudinal length of the central member 550, and so on. A gap orspacing, such as an air gap, may be present between adjacent prongs ineach of the sets. Each of the prongs may be formed from a wide varietyof suitable materials and/or with a wide variety of suitable dimensions.As shown, each of the prongs is formed from a shielding and/or heat sinkmaterial. In other embodiments, a portion of the prongs may be formedfrom shielding and/or heat sink material while another portion of theprongs is formed from other materials (e.g., dielectric materials, flameretardant materials, etc.). Further, as desired, only a portion of agiven prong may be formed from or include shielding and/or heat sinkmaterial. Indeed, prongs may be formed with a wide variety of suitableconstructions.

As desired, the construction of prongs may be varied within a given setof prongs and/or between sets of prongs. For example, a first set ofprongs may be formed as heat sinks while another set of prongs is formedfrom alternate materials (e.g., dielectric material, etc.). As desired,dimensions of prongs may vary between different sets. For example, afirst set of prongs that functions as heat sinks may have firstlongitudinal lengths, and a second set of prongs formed from differentmaterials may have second longitudinal lengths. Additionally, althoughFIG. 5G only illustrates prongs that do not extend along thelongitudinal length of the central member 550, in other embodiments, aportion of the prongs may be continuous along the longitudinal length ofthe central member 550 while another portion of the prongs does notextend along the longitudinal length. Indeed, a wide variety of suitableprong arrangements and/or constructions may be utilized in variousembodiments, and those described herein are provided by way ofnon-limiting example only.

The central members illustrated in FIGS. 5A-5G are continuous alongtheir entire longitudinal length. In other words, each of the centralmembers includes at least one portion that is continuous along theentire longitudinal length. In other embodiments, a central member maybe formed from a plurality of severed or discrete portions that arearranged adjacent to one another (e.g., end to end) along a longitudinallength of a cable. FIGS. 5H and 5I illustrate examples of severedcentral members that include a plurality of discrete portions. Much likethe central members discussed above with reference to FIGS. 5A-5G, thecentral members of FIGS. 5H and 5I may include at least one longitudinalchannel and, as desired, second channel(s), shielding material, prongs,and/or heat sinks.

Turning first to FIG. 5H, a first example severed central member 560 isillustrated. The central member 560 may include any number of discretesegments or portions, such as segments 562A and 562B. None of thesegments or portions will individually extend along an entirelongitudinal length of the central member 560 or a cable into which thecentral member 560 is incorporated. However, the segments may bearranged end to end in order to form a longitudinally extending centralmember 560. As explained in greater detail above with reference to FIG.1, each of the segments may have a wide variety of constructions and/ordimensions (e.g., cross-sectional shapes, lengths, etc.).

A respective longitudinal channel is formed through a body portion ofeach of the illustrated segments 562A, 562B. When the segments arearranged end to end, a single longitudinal channel 564 may extend alongthe length of the central member 560. In certain embodiments, thesegments may be arranged such that they contact one another at theedges. Such an arrangement provides for enhanced flexibility of thecentral member 560; however, the longitudinal channel 564 may beapproximately continuous along the central member's length. As desired,one or more of the segments 562A, 562B may additionally include one ormore second channels formed from the longitudinal channel 564 to anexternal surface.

Additionally, in certain embodiments, shielding material may beincorporated into one or more segments 562A, 562B of the central member564. For example, as illustrated, shielding material may be formed onone or more surfaces of one or more central member segments 562A, 562B,such as a surface of the longitudinal channel 564 and/or on an externalsurface. In certain embodiments, a single patch of shielding materialmay be formed on each central member segment. Additionally, theshielding material formed on a segment may not extend all the way to atleast one of the longitudinal edges of the segment. In other words, adielectric portion may be situated on at least one longitudinal end ofthe segment. As a result, when the segments are longitudinally arranged,a discontinuous shielding arrangement may be formed along thelongitudinal length of the central member 560. In other embodiments, aplurality of patches of shielding material may be formed on a surface ofa central member segment. Additionally, although the central member 560of FIG. 5H includes patches of shielding material formed on one or moresurfaces, other suitable techniques may be utilized to incorporateshielding material into one or more central member segments as describedin greater detail above.

FIG. 5I illustrates another example severed central member 570. Thecentral member 570 may include any number of discrete segments that maybe arranged in a longitudinal manner. Additionally, the central member570 may include one or more longitudinal channels and, as desired, anynumber of second channels. In certain embodiments, at least two of thecentral member segments may be formed from different materials and/ormay have a different construction. For example, a first segment 572A maybe formed from a first set of one or more materials, and a secondsegment 572B may be formed from a second set of one or more materials.In one example embodiment, a first segment 572A may be formed from oneor more polymeric materials, flame retardant materials and/or othersuitable materials while a second segment 572B may be formed from one ormore shielding materials (e.g., electrically conductive material,semi-conductive material, dielectric shielding material, etc.). A widevariety of other segment constructions may be utilized as desired.Additionally, each segment may have any suitable length and/or otherdimensions.

As desired in various embodiments, central members may be formed with awide variety of suitable cross-sectional shapes and/or constructions.FIGS. 6A-6H illustrate cross-sectional views of example central membersthat may be utilized in accordance with various embodiments of thedisclosure. FIG. 6A illustrates an example central member 600 having arod shape. The central member 600 may have a circular or ellipticalcross-section, and at least one longitudinal channel 602 may be formedthrough the central member 600. As shown, the longitudinal channel 602may have a relatively circular cross-sectional shape; however, in otherembodiments, the longitudinal channel 602 may be formed with othersuitable shapes (e.g., rectangular, square, elliptical, etc.).

The central member 600 is illustrated as including a single longitudinalchannel 602; however, in other embodiments such as those illustrated inFIGS. 6B-D and 6H, the central member 600 may include a plurality oflongitudinal channels. Additionally, the central member 600 has a bodyportion with a relatively uniform thickness. In other embodiments, athickness of the central member 600 may be varied at different locationsat any given cross-sectional location. Further, the longitudinal channel602 may be formed with a wide variety of suitable shapes and/ordimensions. As shown, the longitudinal channel 602 has a round orcircular cross-sectional shape. In other embodiments, the longitudinalchannel 602 may have an elliptical, rectangular, square, or othersuitable shape.

FIG. 6B illustrates another example rod shaped central member 610 thatincludes a plurality of longitudinal channels 612, 614. Additionally,the central member 610 may include one or more internal ribs or dividers616 positioned within an internal cavity. In certain embodiments, theinternal rib(s) 616 may provide structural support to the central member610 and/or assist the central member 610 in maintaining its shape.Additionally, the internal rib(s) 616 may divide an internal cavity intoany desired number of longitudinal channels, such as the twolongitudinal channels 612, 614 illustrated in FIG. 6B. With continuedreference to FIG. 6B, the central member 610 is illustrated as beingformed (e.g., molded from, extruded as, etc.) from one or more suitableshielding materials, such as semi-conductive or dielectric shieldingmaterial. Indeed, as set forth above, a central member 610 may be formedfrom any suitable material and/or groups of materials.

FIG. 6C illustrates another example rod shaped central member 620 thatincludes a plurality of longitudinal channels, such as the four depictedchannels 622, 624, 626, 628. For central members with multiplelongitudinal channels, the longitudinal channels may be arranged in anysuitable configuration. For example, as illustrated in FIG. 6C, thelongitudinal channels may be positioned in a cross arrangement. In otherembodiments, such as the central member 610 illustrated in FIG. 6B, twoor more longitudinal channels may be arranged in a side by side or topand bottom configuration. In other embodiments, longitudinal channelsmay be formed in one or more suitable rows. Other configurations ofchannels may be incorporated into central members as desired in otherembodiments. Additionally, the central member and/or longitudinalchannels may include any suitable dimensions.

In certain embodiments, a central member may have a relatively uniformbody portion that is formed from the same material or group ofmaterials. In other embodiments, different components of the centralmember body may be formed from different materials. For example, withreference to FIG. 6D, the internal rib(s) 632 or internal supportstructure may be formed from different materials than the outerrod-shaped or tube portion of the central member 630. In certainembodiments, the outer rod-shaped portion may be formed from one or morepolymeric or dielectric materials (which may have shielding materialformed on one or more surfaces), and the internal rib(s) 632 may beformed from and/or include one or more heat sink materials. For example,the internal rib(s) 632 may be formed from one or more metallicmaterials and/or include one or more longitudinally spaced metallicportions that function as heat sinks within the central member 630.Other suitable constructions and/or groups of materials may be utilizedas desired in other embodiments.

FIG. 6E illustrates an example central member 640 that includes one ormore prongs 642A-F or fins extended from a central portion 644. Asshown, the central member 640 includes six prongs 642A-F extending froma central portion 644. However, as desired in other embodiments, anyother suitable number of prongs may be utilized and/or one or more ofthe prongs may be offset such that it does not extend from a centralpoint. Additionally, as desired, one or more extensions (not shown) mayextend laterally from the ends of one or more of the prongs. Theextensions may be configured to contact the outer jacket of a cable (orany intermediate shielding or other layer) and may assist in holding thecentral member 640 in place. Additionally, any number of longitudinalchannels 646 may be formed within the central portion 644 and, incertain embodiments, within one or more of the prongs 642A-F.

FIG. 6F illustrates another example central member 650 that includes oneor more prongs 652A-F extending from a central portion 654. However, incontrast to the central member 640 of FIG. 6E, the prongs 652A-F of thecentral member 650 may be formed from a different material or group ofmaterials than the central portion 654. As shown, the prongs 652A-F maybe formed at least in part from shielding material, such as electricallyconductive material. Additionally, in certain embodiments, the prongs652A-F may function as heat sinks that serve to pull heat into one ormore longitudinal channels 656 formed through the central member 650.

The central members illustrated in FIGS. 6A-6F all have either arod-shaped or circular cross-section with optional prongs extendingtherefrom. In other embodiments, central members may be formed with awide variety of other cross-sectional shapes. For example, FIG. 6Nillustrates an example central member 660 having a diamond-shapedcross-section. The central member 660 may include any number oflongitudinal channels formed through a body portion, such as theillustrated longitudinal channel 662 that also has a diamond shape.Other channels may include other shapes, and the various components ofthe central member 660 may include a wide variety of suitabledimensions. In other embodiments, as illustrated by the central member670 depicted in FIG. 6H, one or more ribs or support segments may beincorporated into an internal cavity in order to form a plurality oflongitudinal channels and/or to assist the diamond central member 670 inmaintaining its shape. Much like the central member 630 of FIG. 6D, incertain embodiments, the ribs or support segments may be formed from oneor more materials that are different from the material(s) utilized toform an outer portion of the central member 670. Any number ofcomponents (e.g., twisted pair components, etc.) may be positionedaround a diamond-shaped central member. For example, four components maybe incorporated into a cable and positioned adjacent to each of the fourouter surfaces of a diamond-shaped central member.

A wide variety of other suitable central members may be utilized inother embodiments. These central members may include any suitable shapesand/or dimensions. Additionally, central members may include any of thefeatures and/or combination of features described and illustrated abovewith respect to FIGS. 5A-5I. The central members discussed herein areprovided by way of non-limiting example only.

As set forth above, a wide variety of different shielding configurationsand/or arrangements of shielding material may be utilized in conjunctionwith central members, separators, shields, and/or other shield elements.FIGS. 7A-7G illustrate top level views of example shielding materialconfigurations that may be utilized in various embodiments. Theseconfigurations are applicable to one or more central member surfaces(e.g., an outer surface, the surface of a longitudinal channel, etc.),separator surfaces, shielding layer surfaces, embedded layers ofshielding material incorporating into a shield element, segments of asevered shield element, etc. With reference to FIG. 7A, an exampleshield element 770 may include relatively continuous shielding material705. For example, a continuous patch of shielding material may be formedon a surface of the shielding element 770. As another example, ashielding structure 700 may be formed from a shielding material orimpregnated with shielding material along its entire length.

With reference to FIG. 7B, a top level view of another example shieldelement 710 is illustrated. The shield element 710 may include anynumber of rectangular patches of shielding material, such as patches715A-D formed on a dielectric material or otherwise incorporated intothe shield element. As desired in various embodiments, the patches715A-D may include any desired lengths, and any desired gap 720 orseparation distance may be provided between adjacent patches. In certainembodiments, the patches may be formed in accordance with a repeatingpattern having a definite step or period. As desired, additional patchesmay be formed on an opposing side of the dielectric material to coverthe gaps 720.

FIG. 7C illustrates a top level view of another example shield element730. The shield element 730 may include any number of patches ofshielding material having the shape of a parallelogram. In other words,the patches may be formed at an angle within one or more areas of theshield element 730. As shown, the patches may be formed at an acuteangle with respect to the width dimension of the shield element 730. Incertain embodiments, the acute angle facilitates manufacturing and/orenhances patch-to-substrate adhesion. Additionally, the acute angle mayalso facilitate the covering of opposing isolating spaces or gaps. Incertain embodiments, benefit may be achieved when the acute angle isabout 45 degrees or less. In other embodiments, benefit is achieved whenthe acute angle is about 35 degrees or less, about 30 degrees or less,about 25 degrees or less, about 20 degrees or less, or about 15 degreesor less. In other embodiments, benefit is achieved when the acute angleis between about 12 and 40 degrees. In certain embodiments, the acuteangle may be in a range between any two of the degree values provided inthis paragraph or a range bounded on a minimum or maximum end by one ofthe provided values. FIG. 7D illustrates a top level view of anotherexample shield element 740 that may be utilized in various embodiments.The structure 740 may include any number of patches of shieldingmaterial having a trapezoidal shape. In certain embodiments, theorientation of adjacent trapezoidal patches may alternate. Similar tothe patch pattern illustrated in FIG. 7C, the trapezoidal patches mayprovide manufacturing and/or shielding benefits.

In certain embodiments, patches of shielding material may be formedacross a dimension of a shield element, such as across a width dimensionthat is perpendicular to a longitudinally extending direction of theshield element. In other embodiments, multiple patches may be formedacross a given dimension, such as a width dimension. FIG. 7E illustratesa top level view of an example shield element 750 in which multiplepatches are formed across a width dimension. As desired, patches may bediscrete or discontinuous along any dimension of the shield element 750and/or across multiple dimensions (e.g., a width and a lengthdimension). Additionally, any number of patches may be formed across agiven dimension. Each patch may have a wide variety of suitabledimensions (e.g., widths, lengths, etc.), and/or a wide variety ofsuitable separation gaps may be formed between adjacent patches.

FIG. 7F illustrates a top level view of an example shield element 760 inwhich one or more respective microcuts are utilized to form gaps betweenadjacent patches of shielding material. In certain embodiments, thewidth of each of these microcuts may be less than or equal toapproximately 0.25 mm. These relatively narrow microcuts may limit theleakage of the shield element 760, and therefore, reduce noise duringelectrical transmission using a cable. In certain embodiments, a seriesof microcuts may be placed in relatively close proximity to one another.For example, a series of microcuts may be formed as an alternative to atraditional space or gap between patches of shielding material. As oneexample, a conventional discontinuous shield may include gaps or spacesbetween adjacent patches that are at least approximately 0.050 inches(approximately 1.27 mm) wide. By contrast, a plurality of relativelynarrow or fine microcuts (e.g., microcuts of approximately 0.25 mm,etc.) may be formed in an approximately 0.050 inch wide portion (or anyother desired width) of a shield element. Additionally, it is noted thatthe use of singular or isolated microcuts within a shield element mayallow electricity to arc across the microcuts, thereby leading to asafety hazard. However, a plurality of microcuts positioned or formed inrelatively close proximity to one another may limit safety risks due toelectrical arcing. Any electrical arcing across the microcut gaps willlikely burn up or destroy the electrically conductive material betweenthe closely spaced microcuts, thereby breaking or severing theelectrical continuity of the shield element and preventing current frompropagating down the shield element. In other words, the microcuts maybe spaced and/or formed to result in a shield element that includesshielding material having a sufficiently low mass such that theshielding material will fuse or melt when current is applied.

Although the examples above describe situations in which conventionalspaces or gaps are respectively replaced with a series of microcuts, awide variety of other suitable configurations of microcuts may beutilized in other embodiments. For example, a shield element may includemicrocuts continuously spaced in close proximity to one another along alongitudinal length of the shield element. In other embodiments,sections or patches of microcuts may be spaced at regular intervals orin accordance with any desired pattern. Each section or patch mayinclude at least two microcuts. A wide variety of suitable patterns maybe formed by microcuts. For example, a section of microcuts (e.g., onesection of a repeating pattern, etc.) may include microcuts having aperpendicular line pattern, a dashed vertical line pattern, a squarepattern, an inverse square pattern, a diamond-shaped pattern, an inversediamond-shaped pattern, a checkerboard pattern, an angled line pattern,a curved line pattern, or any other desired pattern. As another example,a section of microcuts may include microcuts that form one or morealphanumeric characters, graphics, and/or logos. In this regard, productidentification information, manufacturer identification information,safety instructions, and/or other desired information may be displayedon a shield element. In yet other embodiments, sections or patches ofmicrocuts may be positioned in random locations along a shield element.Additionally, a wide variety of suitable methods and/or techniques maybe utilized to form microcuts. For example, one or more lasers may beutilized to form microcuts.

FIG. 7G depicts a top level view of another example shield element 770that may be utilized in various embodiments. The shield element 770 mayinclude a plurality of discontinuous patches or sections of shieldingmaterial that are formed in a random or pseudo-random manner. A widevariety of other suitable patch configurations and/or otherconfigurations of shielding material may be utilized as desired in otherembodiments, and the configurations discussed herein are provided by wayof non-limiting example only.

Conditional language, such as, among others, “can,” “could,” “might,” or“may,” unless specifically stated otherwise, or otherwise understoodwithin the context as used, is generally intended to convey that certainembodiments could include, while other embodiments do not include,certain features, elements, and/or operations. Thus, such conditionallanguage is not generally intended to imply that features, elements,and/or operations are in any way required for one or more embodiments orthat one or more embodiments necessarily include logic for deciding,with or without user input or prompting, whether these features,elements, and/or operations are included or are to be performed in anyparticular embodiment.

Many modifications and other embodiments of the disclosure set forthherein will be apparent having the benefit of the teachings presented inthe foregoing descriptions and the associated drawings. Therefore, it isto be understood that the disclosure is not to be limited to thespecific embodiments disclosed and that modifications and otherembodiments are intended to be included within the scope of the appendedclaims. Although specific terms are employed herein, they are used in ageneric and descriptive sense only and not for purposes of limitation.

That which is claimed:
 1. A cable comprising: a central member extendinglengthwise along a longitudinal length of the cable, the central membercomprising a channel extending lengthwise and defining a longitudinalcavity through the central member, the channel comprising across-sectional area of at least approximately 0.8 mm²; a plurality oftwisted pair components formed around the central member, each componentcomprising: a plurality of twisted pairs of individually insulatedelectrical conductors; and at least one shield layer comprisingelectrically conductive material, the shield layer formed around atleast one of the plurality of twisted pairs and the shield layer indirect contact with the central member; and a jacket formed around thecentral member and the plurality of twisted pair components.
 2. Thecable of claim 1, wherein the electrically conductive material of the atleast one shield layer comprises first electrically conductive material,and further comprising second electrically conductive materialincorporated into the central member.
 3. The cable of claim 2, whereinthe second electrically conductive material is formed on at least one of(i) the surface of the channel or (ii) an outer surface of the centralmember.
 4. The cable of claim 2, wherein the second electricallyconductive material comprises a plurality of discontinuous patches ofmaterial.
 5. The cable of claim 1, wherein the channel comprises a firstchannel, and further comprising: at least one second channel extendingfrom the first channel to an outer periphery of the central member. 6.The cable of claim 5, wherein the at least one second channel comprisesa plurality of second channels positioned at respective cross-sectionallocations along the longitudinal length.
 7. The cable of claim 1,wherein the channel comprises a first channel and the cavity comprises afirst cavity, and further comprising a second channel extendinglengthwise through the central member and defining a second longitudinalcavity through the central member.
 8. The cable of claim 1, wherein thecentral member further comprises a plurality of prongs that extend froma central portion, each prong extending between two of the plurality oftwisted pair components.
 9. The cable of claim 1, further comprising atleast one heat sink incorporated into the central member.
 10. The cableof claim 1, wherein the plurality of twisted pair components comprisessix twisted pair components.
 11. A cable comprising: a central memberextending lengthwise along a longitudinal length of the cable, thecentral member comprising a body portion and at least one channelextending lengthwise to define a longitudinal cavity through the bodyportion, the at least one channel comprising a cross-sectional area ofat least approximately 0.8 mm²; a plurality of unjacketed twisted paircomponents formed in a ring around the central member, each componentcomprising: a plurality of twisted pairs of individually insulatedelectrical conductors; and at least one shield layer formed around atleast one of the plurality of twisted pairs and comprising electricallyconductive material; and a jacket formed around the central member andthe plurality of twisted pair components.
 12. The cable of claim 11,wherein the electrically conductive material of the at least one shieldlayer comprises first electrically conductive material, and furthercomprising second electrically conductive material incorporated into thecentral member.
 13. The cable of claim 12, wherein the secondelectrically conductive material comprises a plurality of discontinuouspatches of material.
 14. The cable of claim 11, wherein the at least onechannel comprises a first channel, and further comprising at least onesecond channel extending from the first channel to an outer periphery ofthe central member.
 15. The cable of claim 14, wherein the at least onesecond channel comprises a plurality of second channels positioned atrespective cross-sectional locations along the longitudinal length. 16.A cable comprising: a jacket defining a cable core; an enclosed coolingtube positioned within the cable core and configured to longitudinallytransmit a cooling substance provided to the cooling tube from at leastone end of the cable; and a plurality of twisted pair componentspositioned within the cable core around the cooling tube, each of thetwisted pair components comprising: a plurality of twisted pairs ofindividually insulated electrical conductors; and at least one shieldlayer comprising shielding material, the shield layer around at leastone of the plurality of twisted pairs and in contact with the coolingtube; and a jacket formed around the central member and the plurality oftwisted pair components.
 17. The cable of claim 16, wherein theshielding material comprises at least one of (i) electrically conductivematerial or (ii) semi-conductive material.
 18. The cable of claim 16,wherein shielding material of the at least one shield layer comprisesfirst shielding material, and further comprising second shieldingmaterial incorporated into the cooling tube.
 19. The cable of claim 18,wherein the second shielding material comprises a plurality ofdiscontinuous patches of material.
 20. The cable of claim 16, whereinthe cooling tube comprises at least one element extending from a centralportion between two of the plurality of twisted pair components.